1327 751 101a

REPAIR MANUAL
ZF-AS Tronic
Trucks
Repair level 1 - 2
Maintenance, diagnosis, replacement of components
1327 751 101a
CAUTION
The ZF order numbers listed in this document apply
to standard ZF products.
Variances are possible depending on the vehicle
manufacturer.
The binding ZF order numbers are listed in the
relevant parts list parts list no. can be found on the
transmission type plate.
Subject to technical modifications.
Copyright by ZF Friedrichshafen AG
This document is protected by copyright. Any form of
reproduction or dissemination not wholly corresponding
to the intended use of this documentation is prohibited
without the approval of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2000-02
Edition: 2003-05
1327 751 101a
ZF-AS Tronic
Table of contents
Page
Overview of amendments ...........................................................................................................................

Preface ........................................................................................................................................................
Important information.................................................................................................................................
Instructions for carrying out repairs............................................................................................................
Tightening torques ......................................................................................................................................
Changing from DIN to ISO standard codes ................................................................................................
Test device, diagnosis tool...........................................................................................................................
ZF-Intarder diagnosis tool...........................................................................................................................
5
7
8
9
11
13
15
20
1
Maintenance ..............................................................................................................................................
1.1 Visual inspection of wiring .........................................................................................................................
1.2 Maintenance of pneumatic system .............................................................................................................
1.3 Type plate ....................................................................................................................................................
1.4 Approved oil grades ....................................................................................................................................
1.5 Oil volume ..................................................................................................................................................
1.6 Transmission breather .................................................................................................................................
1.7 Oil change intervals ....................................................................................................................................
1.8 Oil level check.............................................................................................................................................
1.9 Oil change (transmission without ZF-Intarder) ..........................................................................................
1.9.1 Filling oil.....................................................................................................................................................
1.10 Oil level check.............................................................................................................................................
1.11 Instruction plate for oil change ...................................................................................................................
1.12 Oil change (transmission with ZF-Intarder) ...............................................................................................
1.13 Oil filter change ..........................................................................................................................................
1.14 Oil filling ....................................................................................................................................................
1.14.1 Oil filling during an oil change ..................................................................................................................
1.14.2 Oil filling after transmission repairs...........................................................................................................
1.15 Engine coolant ............................................................................................................................................
1.16 ZF-Intarder type plate .................................................................................................................................
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-4
1-5
1-5
1-6
1-7
1-7
1-7
1-8
1-8
2
2.1
2.2
2.3
Diagnosis ....................................................................................................................................................
Diagnosis for vehicles with ZF display and ZF range selector....................................................................
Diagnosis with TestmanPro.........................................................................................................................
Transmission actuator data sheet.................................................................................................................
2-1
2-1
2-2
2-3
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2
3.2.1
3.2.2
3.2.3
3.2.4
Component replacement...........................................................................................................................
Transmission actuator .................................................................................................................................
Removing transmission actuator .................................................................................................................
Fitting..........................................................................................................................................................
Dismantling transmission actuator..............................................................................................................
Assembling transmission actuator ..............................................................................................................
Programming transmission actuator............................................................................................................
Replacing pressure limitation valve ............................................................................................................
Clutch actuator ............................................................................................................................................
Removal ......................................................................................................................................................
Push rod ......................................................................................................................................................
IVECO push rod setting ..............................................................................................................................
Fitting..........................................................................................................................................................
3-1
3-1
3-1
3-3
3-5
3-5
3-6
3-6
3-7
3-7
3-8
3-9
3-10
1327 751 101 - 2003-04
ZF-AS Tronic
Table of contents
Page
3.3 Replacement of driver disc..........................................................................................................................

3.3.1 Fitting engine, clutch and transmission.......................................................................................................
3.4 Clutch release mechanism...........................................................................................................................
3.4.1 Removal of release fork ..............................................................................................................................
3.4.2 Fitting release fork ......................................................................................................................................
3.5 Output flange ..............................................................................................................................................
3.5.1 Removal .....................................................................................................................................................
3.5.2 Fitting .........................................................................................................................................................
3.5.3 Removing output cover ...............................................................................................................................
3.5.4 Fitting output cover .....................................................................................................................................
3.6 Speed sensor (impulse sensor), output, depends on vehicle manufacturer .................................................
3.6.1 Removal .....................................................................................................................................................
3.6.2 Fitting .........................................................................................................................................................
3.6.3 Connector replacement ...............................................................................................................................
3.7 Replacing Neutral switch ............................................................................................................................
3.7.1 Removal .....................................................................................................................................................
3.7.2 Fitting .........................................................................................................................................................
3.7.3 Connector replacement ...............................................................................................................................
3.8 Replacing components on Intarder .............................................................................................................
3.8.1 Speed sensor, output....................................................................................................................................
3.8.2 Tacho sensor................................................................................................................................................
3.8.3 Solenoid valve.............................................................................................................................................
3.8.4 Temperature sensor .....................................................................................................................................
3.8.5 Removing 3/2-way valve.............................................................................................................................
3.8.6 Removing / fitting Intarder wiring harness .................................................................................................
3.9 Additional cooling connection ....................................................................................................................
3.10 Display .......................................................................................................................................................
3.10.1 Disassembly................................................................................................................................................
3.10.2 Installation..................................................................................................................................................
3.10.3 Connection diagram ...................................................................................................................................
3.10.4 Connector replacement...............................................................................................................................
3-12
3-12
3-13
3-13
3-14
3-15
3-15
3-15
3-16
3-16
3-17
3-17
3-17
3-17
3-18
3-18
3-18
3-18
3-19
3-19
3-19
3-19
3-19
3-20
3-20
3-21
3-22
3-22
3-22
3-22
3-22
Annex
Documents / drawings attached................................................................................................................... 3-23
Connector and mating connector designations............................................................................................ 3-24
Pneumatics diagram .................................................................................................................................... 3-25
1327 751 101 - 2003-04
ZF-AS Tronic
Index Issue date

a
1327 751 101 - 2003-04
Overview of amendments: 1327 751 101
Chapter Initiator
BKS/LKS
Comments
Complete revision:
Maintenance included, diagnosis extended,
repair work updated. Repair manual, level 1-2 divided
up into truck 1327 751 101 and bus 1337 751 101
ZF-AS Tronic
Preface
This document has been written for skilled staff who
have been trained by ZF Friedrichshafen AG to carry
out maintenance and repair work on ZF products.
This manual refers to a volume production ZF product in accordance with the state of development on
the date of issue.
However, due to further technical developments, repair
work on your unit may require other work practices and
other test or adjustment data which are not contained in
this manual.
We therefore recommend that you entrust your ZF product to supervisors and fitters who have had their practical and theoretical knowledge updated on a regular basis
at our Service-Training-Center.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained staff
2. Specified equipment,
e.g: special tools
3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out

conscientiously and with care.
Warranty:
Repair work carried out at ZF service points is covered by warranty in accordance with the prevailing
contractual conditions.
ZF FRIEDRICHSHAFEN AG
Commercial Vehicle and Special Driveline Technology
Division
Service Werk 2
Tel.: (0 75 41) 77-0
Fax: (0 75 41) 77-908000
Internet: www.zf.com
1327 751 101 - 2003-04
Damage resulting from work performed by non-ZF staff

in an improper and unprofessional manner, together
with any follow-on costs caused by such work, is not
covered by the contractual liability.
This also applies to instances in which genuine ZF
spares have not been used.
ZF-AS Tronic
Important information
SAFETY NOTICE
GENERAL INFORMATION
Companies who repair ZF units are responsible for their

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

repair work.
To avoid injury to staff and damage to products, all

safety regulations and legal requirements which apply
to repair and maintenance work must be observed.
Before starting work, mechanics must familiarize
themselves with these regulations.
Staff 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 are properly trained.
CAUTION
Pictures, drawings and components shown do not
always represent the original object but are simply
used to illustrate working procedures. Pictures,
drawings and components are not to scale and no
information about size and weight should be inferred
(even within a complete drawing).
Always follow the working steps as described in the
text.
The following safety instructions appear in this

manual
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
correctly.
! THREATS TO THE ENVIRONMENT
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water or sewage system.
Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants
and cleaning agents in accordance with
environmental protection guidelines.
When working with lubricants and cleaning
agents, always refer to the manufacturers
instructions.
NOTE
Refers to special process, techniques, data, use of
auxiliary equipment etc.
CAUTION
This is used if other 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 hung on the input
shaft NOR on the output flange.
1327 751 101 - 2003-04
ZF-AS Tronic
Instructions for carrying out repairs

GASKETS, LOCKING PLATES
In any instances of doubt, always contact the relevant

specialist department within ZF After-Sales Service
for advice.
Ensure cleanliness and professional work whenever
working on the transmission.
The intended tools must be used to dismantle and
assemble the transmission.
Parts which cannot be removed without being damaged

must always be replaced with new parts (e.g. gaskets
and locking plates).
SHAFT SEALS
Always change shaft seals with rough, ripped or hardened seal lips. Seal contact surfaces must be totally clean
and in perfect condition.
After removing the transmission from the vehicle, clean

thoroughly with appropriate washing agent before opening.
Pay particular attention to the corners and angles of
housings and covers when cleaning with appropriate
washing agent.
REWORKING
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower.
Rework may only be carried out on the seal contact surfaces using plunge-cut grinding. Never use an emery
cloth. Ensure there are no traces of grinding or rifling
from grinding.
CLEANING PARTS
Remove old remains of gaskets from all sealing faces.
Carefully remove burrs or other similar patches of
roughness using an oil stone.
If rework is needed on spacer washers or shims etc.

because of clearance settings, ensure that the reworked
areas contain no face runout and are of the same surface
quality.
Lube bores and grooves must be free of anti-corrosion

agents and foreign bodies. Check that they can move
freely.
TRANSMISSION ASSEMBLY
Find a clean site to assemble the transmission.
Gaskets are fitted without the use of sealing compound
or grease. When measuring silicon-coated gaskets, take
care not to include the silicon layer in the
measurement.
During transmission assembly, comply with all
adjustment data and tightening torques specified in the
repair manual.
Carefully cover opened transmissions to prevent the

entry of foreign matter.
REUSING PARTS
A competent person must inspect parts such as ball or
roller bearings, multi-discs, thrust washers etc. to decide
whether they can be reused or not.
Replace parts which are damaged or have suffered from
excessive wear.
1327 751 101 - 2003-04
ZF-AS Tronic
Instructions for carrying out repairs

d) Duo shaft seals have two sealing
lips. The dust protection sealing lip
(X) must face outwards.
BEARINGS
If the bearings are fitted while hot, these should be heated accordingly (e.g. in a heating cabinet).
The temperature should be approx. 85 C and must not
exceed 120 C. All bearings fitted must be coated with
operating oil after assembly.
e) Fill the gap between the sealing

lips so that it is 60 % filled with grease* (use a
grease e.g. produced by Aral such as Aralub HL2 or
produced by DEA such as Spectron FO 20).
f) If possible, heat shaft seal bores to between 40 and
50 C (this makes fitting easier).
Press the shaft seal with mounting or face plate evenly into the relevant installation depth.
SEALING
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturers directions for use. The
sealing agent should be applied to the surfaces in thin
layers and must be spread evenly. Do not allow sealing
agent to enter oil ducts and bores. The sealing agent
should be wiped off oil-carrying ducts and bores from
the surfaces to be sealed near apertures to ensure that no
sealing agent penetrates the oil feeds when the surfaces
are sealed.
RETAINING AGENTS
Retaining agents* may only be used in those places
specified in the parts list.
Always comply with the manufacturers directions of
use when using retaining agents (e.g. Loctite).
During assembly, observe all adjustment data, checking
data and tightening torques.
SHAFT SEALS
a) Apply a thin coat of sealing agent* on outer edge of
shaft seals with steel surround.
TRANSMISSION OIL
After completing repairs, fill the transmission with
transmission oil. For the procedure and approved oils,
refer to the transmission operating manual and List of
Lubricants TE-ML (refer to type plate). These
documents are available from all ZF After-Sales Service
points and can be found on the Internet at www.zf.com.
After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
specified torques.
b) Never apply sealing agent to shaft seals with rubber surround but apply a thin coat of Vaseline 8420
to the outer edge or spray with a lubricant, such as a
water-soluble, concentrated washing-up liquid (e.g.
Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber surrounds should be
treated as shaft seals (described above in section (b))
on the outer edge of the rubber surround.
* refer to consumables
1327 751 101 - 2003-04
10
ZF-AS Tronic
Tightening torques
Tightening torques for nuts and bolts, extract from

ZFN 148
Surface condition of bolts/nuts: heat-treated blackened
finish and oiled or galvanized and oiled or galvanized,
chrome-plated and oiled.
This standard applies to bolts as defined in 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 as defined in DIN 934 as well as ISO 4032, ISO
8673.
The bolts are tightened using a calibrated snap torque

wrench or torque display wrench.
This standard contains data on tightening torques for

bolts and nuts in strength categories 8.8, 10.9 and 12.9,
as well as nuts in strength categories 8, 10 and 12.
NOTE
Divergent tightening torques are listed separately in the
repair manual.
Metric standard pitch thread
Metric course pitch thread
Size
Size
Bolt
Nut
Tightening torque
in Nm for
8.8
10.9
8
10
12.9
12
M4
M5
M6
2.8
5.5
9.5
4.1
8.1
14
4.8
9.5
16.5
M7
M8
M10
15
23
46
23
34
68
M12
M14
M16
79
125
195
M18
M20
M22
M24
M27
M30
Bolt
Nut
Tightening torque
in Nm for
8.8
10.9
8
10
12.9
12
M8x1
M9x1
M10x1
24
36
52
36
53
76
43
62
89
28
40
79
M10x1.25
M12x1.25
M12x1.5
49
87
83
72
125
120
84
150
145
115
185
280
135
215
330
M14x1.5
M16x1.5
M18x1.5
135
205
310
200
300
440
235
360
520
280
390
530
390
560
750
460
650
880
M18x2
M20x1.5
M22x1.5
290
430
580
420
620
820
490
720
960
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
1327 751 101 - 2003-04
11
ZF-AS Tronic
Tightening torques
Screw plugs DIN 908, 910 and 7604
Union screws DIN 7643
The values of the screw plug tightening torques were

determined according to DIN 7604 for screwing into
steel, grey cast and aluminium alloys.
The values are based on experience and are only
intended as reference values for the fitter.
The values for the tightening torque should also be used
for screw plugs as defined in DIN 908 and DIN 910 as
the thread geometries are almost identical.
General rule: Screw class 5, ZFN 148-1
Screw material: steel acc. to DIN 7604
Surface condition: as manufactured (no
surface protection) and lightly oiled or
galvanized, chrome-plated and lightly
oiled.
The tightening torques were determined for screwing

into steel, grey cast and aluminium alloys.
The values are based on experience and are only
intended as reference values for the fitter.
General rule: Screw class 5, ZFN 148-1
Material: 9SMnPb28K acc. to DIN 1651
Surface condition: as manufactured (no
surface protection) and lightly oiled or
galvanized, chrome-plated and lightly
oiled.
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
Union screws (DIN 7643)
Tightening torque
in Nm screwed into
steel/grey cast Al alloy
20*
25 / 30*
35
35
40
50
55
60 / 80*
70
80 / 105*
80
100 / 130*
95
120
130
140
150
145
160
150
170
160
180
195
205
Pipe
outer
diameter
10*
15 / 20*
25
25
30
35
45
50 / 65*
60
70 / 90*
70
90 / 130*
85
110
115
120
130
125
140
130
145
135
150
165
175
* DIN 7604 Form C
1327 751 101 - 2003-04
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
12
ZF-AS Tronic
Changing from DIN to ISO standard codes
Withdrawn Title
DIN
Replacement Result of testing/measures 1)

ISO standard
DIN 1
Tapered pins
ISO 2339
- some can be interchanged changed to ISO 2339

- parts cannot be interchanged (e.g. when 1 = 36 mm), documented
on DIN 1-ALT
DIN 7
Cylinder pin
ISO 2338

- parts cannot be interchanged (e.g. 13 and 14 and/or 1 = 36 mm),
documented on DIN 7-ALT
DIN 84
Cylindrical
screws
ISO 1207

- parts cannot be interchanged (e.g. M2.6), doc. on DIN 84-ALT
DIN 85
Flat head
screws
ISO 1580
- can be interchanged 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 interchanged documented on DIN 439-ALT
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 cannot be interch. (e.g. M12, new waf), doc. on DIN 558-ALT
DIN 601
Hex bolts
ISO 4016

- parts cannot be interchanged (e.g. M10 and M12, new waf),
DIN 912
Cylindrical
screws
ISO 4762

- parts cannot be interchanged (e.g. M18, M22, M27 and M33),
DIN 931-1
Hex bolts
ISO 4014

- parts cannot be interchanged (e.g. M10, M12, M14 and M22 with
new waf), documented on DIN 931-ALT
DIN 933
Hex bolts
ISO 4017

DIN 934
Hex nuts
ISO 4032
ISO 8673
- cannot be interchanged as a result of different nut heights and

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

DIN 961
Hex bolts
ISO 8676

DIN 963
Countersunk
bolts
ISO 2009
- cannot be interchanged due to different head dimensions,

DIN 964
Countersunk
bolts
ISO 2010
- cannot be interchanged due to different head dimensions,

1) refers to the product parts numbered by ZF
1327 751 101 - 2003-04
13
ZF-AS Tronic
Withdrawn Title
DIN
Changing from DIN to ISO standard codes
Replacement Result of testing/measures 1)

ISO standard
DIN 965
Countersunk bolts ISO7046
- cannot be interchanged due to different head dimensions

DIN 980
Lock nuts
ISO 7042
ISO 10513
DIN 985
Lock nuts
ISO 10511
DIN 1440
Washers
ISO 8738

- parts cannot be interchanged, documented on DIN 1440-ALT
DIN 1443
Bolts
ISO 2340
DIN 1444
Bolts
ISO 2341
DIN 1471
Grooved pins
ISO 8744

- parts cannot be interchanged (e.g. 1 = 6 mm), documented on
DIN 1471-ALT
DIN 1472
Grooved pins
ISO 8745

- parts cannot be interchanged (e.g. 1 = 6 and 25 mm), documented
on DIN 1472-ALT
DIN 1473
Grooved pins
ISO 8740

- parts cannot be interchanged (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 studs
ISO 8746
DIN 1477
Grooved studs
ISO 8747
DIN 1481
Slotted pins
ISO 8752

- parts cannot be interchanged (e.g. 1 = 36), documented on
DIN 1481-ALT
DIN 6325
Cylinder pins
ISO 8734

DIN 6325-ALT
DIN 7346
Slotted pins
Flange
ISO 13337

- parts cannot be interchanged ( 7, 11 and 23 mm), documented on
DIN 6325-ALT
DIN 7976
Tapping screws ISO 1479
DIN 7978
Tapered pins
ISO 8736

DIN 7978-ALT
DIN 7979
Cylinder pins
ISO 8733
ISO 8735
- some can be interchanged changed to ISO 8733/8735

- parts cannot be interchanged, documented on DIN 7979-ALT
DIN 7981
DIN 7982
DIN 7985
Cheese head
screws
ISO 7045
1) refers to the product parts numbered by ZF
1327 751 101 - 2003-04
14
ZF-AS Tronic
Fig.
no.
Test device diagnosis tool
Special tools
Order no.
Application
Qty.
Remarks
1X56 099 063

Adapter
for shaft seal in release flange
1X56 137 124

Adapter
for 105x125x12
shaft seal on output
1X56 138 189

Spacer ring
(used in conjunction with adapter
1X56 137 124)
for Intarder version, 105x125x12
shaft seal on output
1X56 138 215

Adapter
for release for shaft seal
240
Simplifies
assembly
11
15
74
M10
M10
75
60.5
1X56 138 244

64
112
9H7
100.1
25
14
9r6
8.70.1
200.1
2x45
2x45
40
1327 751 101 - 2003-04
2120.1
Setting fixture
for piston rods on transmission actuator
37.50.1
9H7
15
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
6008 208 503
Remarks
Only for ZF sales and
service organizations
TestmanPro, complete
6
Scope of supply
- 6008 208 013 TestmanPro with
DPA04i + cable
- 6008 208 015 Application CD
- 6008 208 016 Licence
6008 208 501
Only for ZF sales and

service organizations
Set for converting Testman to TestmanPro

7
Scope of supply
- 6008 208 011 Update CD
- 6008 208 015 Application CD
- 6008 208 016 Licence
6008 307 009
Electrical adapter cable

MobiDig 2001
To supply voltage in
vehicle via cigarette
lighter
0501 211 104

SAE 1708 cable
9
6008 208 003

TestmanPro for ZF customers
10
1327 751 101 - 2003-04
Scope of supply:
6008 308 601 Cable RS 232
0501 211 103 Cable ISO 9141
6008 308 600 DPA04i
6008 208 900 TestmanPro software
user interface
16
Following agreement
with ZF Friedrichshafen
AG
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Application software
ZF-AS Tronic 2
11
6008 308 019

6008 308 119
6008 308 219
6008 308 319
6008 308 419
Single station licence
de
en
fr
es
it
0501 301 068
12
Remarks
Simple programming device

EPD1
6008 298 029

+ details of program item no.
Programming tool
for control unit
programming
Memory card for control

unit programming
(depends on parts list)
13
PlugIn
6008 207 003

Table mode adapter for AS Tronic
14
Terminal test
6008 006 002 (68-pin)
15
1327 751 101 - 2003-04
17
Adapter cable for programming and configuration purposes as well

as diagnosis outside
vehicle
The terminal tester can

be used to interrupt all
PINs and/or to take
measurements on all
PINs
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
UNIVERSAL
Remarks
Connection:
terminal tester
6008 307 025

16
Universal diagnosis connection for
use with terminal tester
6008 206 007
17
6008 307 026 (5-pin)

6008 307 031 (30-pin)
Diagnosis connection for
transmission and Intarder
MAN
20
6008 207 007 for MAN TGA

6008 207 006 for MAN F2000 + Bus
1327 751 101 - 2003-04
Adapter cable for pin

end, bus and truck
Adapter cable with 68-pin pin for

18/20-pin bush
IVECO
19
Adapter cable for bush

end, bus and truck
Adapter cable with 68-pin bush for

18/20-pin pin
6008 206 006
18
WARNING:
PIN assignment depends
on control unit
18
Connection: 5-pin
diagnosis connection
plug under flap in front
of range selector
Connection: 30-pin
plug near fuse box
Connection:
plug near fuse box.
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
RVI
6008 207 009
21
1327 751 101 - 2003-04

19
Remarks
Connection:
plug near fuse box or
bottom left of drivers
cab
ZF-AS Tronic
Fig.
no.
Special tools
ZF-Intarder diagnosis tool
Order no.
Application
Terminal tester adaptation
Remarks

end, bus and truck
6008 206 011 for EST 42

1
Adapter cable with 68-pin pin for 88pin bush

end, bus and truck
6008 206 012 for EST 42

2
Adapter cable with 68-0 bush for 88pin pin
6008 207 005

EST 42 table mode adapter
3
AS Tronic 2 APPLICATION
SOFTWARE
4
6008 308 011

6008 308 111
6008 308 211
6008 308 311
6008 308 411
de
en
fr
es
it

6008 206 024 for EST 48
5
1327 751 101 - 2003-04
20

as diagnosis outside the
vehicle
Application software
for Intarder EST42/48
(individual station
licence)

end, bus and truck
ZF-AS Tronic
Fig.
no.
Special tools
ZF-Intarder diagnosis tool
Order no.
Application
Remarks

end, bus and truck
6008 206 025 for EST 48

6
6008 207 010

EST 48 table mode adapter
7
1327 751 101 - 2003-04
21

as diagnosis outside the
vehicle
ZF-AS Tronic
Maintenance
Maintenance
1.3
Please also note any information provided by

the vehicle manufacturer
Regular maintenance increases the transmissions

level of operational safety.
The type plate contains the most important pieces of

data.
It can be found on the left-hand side of the transmission,
when viewed from the output.
Visual inspection for oil leaks as part of vehicle

servicing check.
1.1
Visual inspection of wiring
Check wiring for damage as part of vehicle servicing check.
Type plate
The following details must always be provided when

making enquires or undertaking repair work:
transmission type
parts list no. of transmission
transmission volume production no.
MADE IN GERMANY
AS Tronic
Ensure that connectors are seated correctly,

connectors must be fitted with traction relief.
12 AS 2330 TO
MODEL
PARTS LIST NO.
1327 036 001
1.2
Maintenance of pneumatic system
The maintenance instructions of the vehicle
CUSTOMER
SPEC. NO
TOTAL
RATIO
P.T.O.
SPEEDO
RATIO
12.33 - 0.78
xxxxx
n=
11
xxx
xxxxx
OIL GRADE SEE

LUBRIC. LIST TE-ML
xn
ENGINE
02L
019 311
The pneumatic tank should be drained once a

week, in winter this should be done once a day.
Type plate (example)
NOTE
When draining the pneumatic tank, the pneumatic
cleaner and water separator should also be drained
provided that the cleaner does not function
automatically.
xxxxxx
OIL CAPACITY
IN LTS.
manufacturer must be observed.
SERIAL - NO.
00247443
1.4 Approved oil grades

Only those lubricants which are listed in ZF List of
Lubricants TE-ML 02 may be used. ZF List of
Lubricants TE-ML 02 is available from all ZF agents or
on the Internet at http://www.zf.com
The interval for changing cartridges must be

observed in vehicles which are fitted with an air
dryer.
1.5 Oil volume

The oil volume is noted on the type plate.
Oil filling must be undertaken accurately if the correct
volume of oil is to be filled into the transmission. (Refer
to Sections 1.9 and 1.10).
1327 751 101 - 2003-04
1-1
ZF-AS Tronic
Maintenance
1
4
1 Tighten oil drain plug to 60 Nm

2 Tighten oil drain plug to 60 Nm
3 Tighten oil fill plug to 60 Nm
4 Type plate
5 Transmission breather
018 799
1.6
1.8
Transmission breather
The transmission oil heats up during travel. Overpressure therefore builds up and is continuously removed
through a breather valve.
Ensure that the breather valve is functioning at all times.
Do not spray directly with pressurized water (water in
transmission risk of corrosion). The breather (5) must
be clean and not have a plastic cover.
Oil change check (ZF-AS Tronic without

ZF-Intarder)
! DANGER !
Too little oil in the transmission results in transmission damage. RISK OF ACCIDENT
Check the transmission oil level as part of vehicle

servicing:
Undertake oil level check with vehicle on level

ground.
Do not check oil level immediately after travel

(incorrect measurement result). Only undertake
check once the transmission oil has cooled down
(<40 C).
Remove oil filler plug (3).
If the oil level has fallen below the oil filler

aperture, the oil must be topped up
(refer to 1.9.1).
1.7 Oil change intervals

In order to retain the transmissions level of operating
safety, the oil change intervals, as specified in ZF List
of Lubricants TE-ML 02, must be observed.
NOTE
Whenever checking the oil level, the transmission
should also be checked for leaks.
1327 751 101 - 2003-04
1-2
ZF-AS Tronic
Maintenance
1.9.1 Filling oil
1.9 Oil change (ZF-AS Tronic without ZFIntarder)
Fill oil through oil filler aperture (3).
The oil may only be changed when the vehicle is on

level ground and the engine is switched off.
Always change the oil after a long period of travel while

the transmission oil is still at operating temperature and
is still thin.
The oil level is correct when the oil has reached

the bottom edge of the oil filler aperture and/or if
oil is already escaping from the oil filler aperture.
Tighten oil filler plug (3) to 60 Nm.
! DANGER !
Touching hot parts and transmission oil may result
in burns.
Remove oil drain and oil filler plugs (1, 2 and 3)

from transmission and collect transmission oil in
a suitable container and dispose of in accordance
with environmental guidelines.
Clean magnetic plug of oil drain plug (2) and

replace seal.
Tighten oil drain plugs (1 and 2) to 60 Nm.
019248
Fig.: Transmission without Intarder

1 Oil drain plug
2 Oil drain plug
3 Oil filler plug
Oil filler aperture or overflow measurement
1327 751 101 - 2003-04
1-3
ZF-AS Tronic with Intarder
1
2
3
4
Maintenance
Tighten oil drain plug to 60 Nm

Tighten oil drain plug to 60 Nm
Tighten oil filler plug or oil overflow to 60 Nm
Type plate
5
9
10
11
Transmission breather
After repairs, tighten oil filler plug to 60 Nm
Tighten screw to 23 Nm
Filter cover
019 368
NOTE
In order to gain a correct measurement result, the

oil level must be checked when
the vehicle is on level ground.
the engine is switched off
the transmission oil has cooled (< 40 C).
Check the oil level as part of vehicle servicing.
When checking the oil level, also check for leaks in

the following places:
transmission,
Intarder,
oil/water heat exchanger,
associated coolant pipes.
1.10 Oil level check (transmission with ZFIntarder)

! DANGER !
Too little oil in the transmission results in transmission damage. Risk of accident.
CAUTION
To check the oil level, the Intarder must not be activated just before stopping the vehicle.
This ensures that the correct oil volume is set in the
transmission.
CHECK:
Stop the vehicle without activating the Intarder.
When checking the oil level, the oil filler plug (3)
should be removed.
If the oil level has fallen below the edge of the oil
overflow aperture, the oil must be topped up
(refer to 1.14).
1327 751 101 - 2003-04
1-4
Maintenance
1.11 Instruction plate for oil change
! DANGER !
Touching hot parts and transmission oil may result
in burns.
The instruction plate for oil changes, on the oil filler

plug (3), must not be removed.
Switch off engine
Remove oil drain plug (2) from transmission and

oil drain plug (1) from oil filter housing.
Clean solenoids of oil drain plug and replace the

seals.
Replace oil filter (refer to 1.13).
Then, screw in oil drain plugs and tighten to 60

Nm.
OEL WECHSEL
List
SAEof30lubricants
TE-ML 02
1.
EINFUELLEN BIS
UEBERLAUF
2.
PROBEFAHRT OHNE
RETARDERBETRIEB
3.
NACHFUELLEN BIS
UEBERLAUF
001 269
CAUTION
Note the specified tightening torque for the oil drain
plugs; otherwise the transmission may be damaged.
1.12 Oil change (transmission with ZF-Intarder)

CAUTION
The ZF-Intarder must NOT be activated just before
stopping the vehicle for an oil change.
This ensures that the correct oil change volume is set
in the transmission.
NOTE
When changing the oil, collect the oil drained out

in an appropriate container and dispose of in
accordance with environmental guidelines.
Always change oil after a long period of travel

while the transmission oil is still at operating
temperature and is still thin.
Only ever change the oil when the vehicle is on

level ground.
1327 751 101 - 2003-04
1-5
Maintenance
1.13 Oil filter change

NOTE
Whenever changing the oil filter, always use a new oil
filter.
!
DANGER!
With hot transmission oil: risk of burns.
Remove screw (10) from filter cover (11).

10
11
1
000529
Pull off filter cover (11) with attached filter.

Take oil filter of filter cover.
CAUTION
There will be some oil left in the oil filter housing.
000552
On filter cover (11), check O-ring (8) for damage, replace and grease in if necessary.
Securely attach solenoid (12) to new filter.
Grease in O-ring (7).
Place filter cover (11) on new filter (6). Insert

complete unit in filter housing until firmly
home.
11
88
77
66
512
Tighten screw (10) to 23 Nm.
004467
1327 751 101 - 2003-04
1-6
Maintenance
1.14 Oil filling (transmission with ZF-Intarder)

9
WARNING
When working on transmissions with ZF-Intarders, a
distinction is made between oil filling during an oil
change (1.14.1) and oil filling after transmission
repairs (1.14.2)
1.14.1 Oil filling during an oil change

NOTE
The oil may only be filled when the vehicle is on level
ground and the engine is switched off. Oil grade in
accordance with TE-ML 02.
019 367
Fill transmission until oil overflows.
Screw in oil filler plug (3) with new seal and

tighten to 60 Nm.
1.14.2 Oil filling after transmission repairs

NOTE
The oil may only be filled when the vehicle is on level
ground and the engine is switched off. Oil grade in
accordance with TE-ML 02.
Carry out test run: distance 2 - 5 km

Do NOT activate Intarder during test run.
End of test run: vehicle at standstill.

Do NOT activate Intarder.
Remove oil filler plugs (3 and 9).
Fill with oil at pos. 9 until oil overflows at pos. 3
Screw in oil filler plugs (3 and 9) with new seal and

tighten to 60 Nm
Remove oil filler screw (3).
NOTE
The instruction plate on the oil filler screw (3) must not
be removed.
Carry out test run: distance 2 - 5 km

Test run: at start, BRIEFLY activate Intarder (stage 6)
ONCE
CAUTION
Check oil level again and if necessary, top up with oil
until it overflows.
End of test run: vehicle at standstill.

Do NOT activate Intarder.
Screw in oil filler plug (3) with new seal and tighten to 60 Nm.
NOTE
The instruction plate on the oil filler screw (3) must not
be removed.
CAUTION
Check oil level again and if necessary, top up with oil
until it overflows.
1327 751 101 - 2003-04
1-7
Screw in oil filler plug (3) with new seal and tighten to 60 Nm.
Maintenance
1.15 Engine coolant
1.16 ZF-Intarder type plate
CAUTION
When topping up the engine coolant, the specifications of the vehicle manufacturer MUST be
observed. Otherwise the oil/water heat exchanger
may be damaged.
The type plate contains the most important pieces of

data.It can be found to the side of the Intarder housing.
The following items must always be provided when

making enquires or undertaking repair work:
1. parts list no. of Intarder
2. volume production no. of Intarder
Engine coolant
(mixture of fresh water and anti-corrosive
antifreeze)
Recommended volume of anti-corrosive
antifreeze, 35 - 50 vol. %, should be checked
using coolant tester.
MADE IN GERMANY
Intarder
PARTS LIST NO.
Anti-corrosive antifreeze
Base fluid: ethylene glycol with anti-corrosive
inhibitors.
6085 020 028
P.T.O.
N
OIL CAPACITY
IN LTS.
Example of type plate
Change interval for engine coolant:

max. every 2 years (fill in pre-mixed state)
NOTE
If sludge forms or if the concentration suddenly falls, the
coolant must be replaced immediately.
1-8
SERIAL - NO.
XXX XXX
CUSTOMER
SPEC. NO
TOTAL
RATIO
Fresh water
pH value of 6.5 -8.0; total hardness 3-10 dH
1327 751 101 - 2003-04
IT AS Tronic
MODEL
SPEEDO
RATIO
n=
xn
ENGINE
OIL GRADE SEE

LUBRIC. LIST TE-ML
019527
ZF-AS Tronic
Diagnosis
Calling up the error numbers*:
Diagnosis
2.1
Diagnosis for vehicles with ZF display

and ZF range selector
Switch on ignition
Turn rotary switch to N
Hold control lever in + position
For vehicles with their own display, refer to details provided in vehicle manufacturers description
A number shown on the display corresponds to the error

number.
If 4 bars are displayed in addition to the number shown
on a two-digit display, this means:
002 686
ZF display
Error no. + 100

e.g.: error no. 74
error no. 174
003 930
ZF range selector
013 587
When using standard ZF software, system errors are

shown on the ZF display.
If 4 bars and 2 arrows are displayed in addition to the

number shown, this means:
If a screwdriver symbol
appears on the display, there is a
system error.
Only limited operations are
008 026
possible.
For example: with certain system errors, automatic driving mode is deactivated and the transmission system
remains in manual mode.
If a STOP appears on the display together with a screwdriver symbol, there is a serious
system error. The vehicle cannot be driven any further. The vehicle usually
has to be towed away.
Error no. + 200

e.g.: error no. 27
error no. 227
018 470
008 027
* also refer to vehicle manufacturer operating manual
1327 751 101 - 2003-04
2-1
ZF-AS Tronic
2.2
Diagnosis
Diagnosis with TestmanPro
Interrogating error memory
Deleting error memory
1.
Open Testman
1.
Open Testman
2.
Commercial vehicle/special driveline

technology
2.
Commercial vehicle/special driveline

technology
3.
Main menu for AS Tronic 2
3.
Main menu for AS Tronic 2
4.
Licensing
4.
Licensing
5.
Safety information
5.
Safety information
6.
Diagnosis product menu
6.
Diagnosis product menu
7.
Laptop connection information
7.
Laptop connection information
8.
Communication structure
8.
Communication structure
9.
Logbook (is automatically saved in GDS3000

directory under transmission number)
9.
Logbook (is automatically saved in GDS3000

directory under transmission number)
10.
Interrogate diagnosis error memory (transmission

actuator in vehicle, connection via vehicle end
diagnoses interface)
10.
Del diagnosis error memory
11.
Del error memory yes/no
12.
Error memory has been deleted
11.
Interrogate/save error memory
12.
Select error (e.g. here error 191 EOL error)
13.
Interrogate error data (save if possible)
Working with checklists

When handling complaints, it is important that the
checklist is worked through in full and that the data
required is determined. This is the only way in which the
problem can be localized.
1327 751 101 - 2003-04
2-2
ZF-AS Tronic
Transmission actuator data sheet
TECHNICAL DATA / TECHNISCHE DATEN / CARACTERISTIQUES TECHNIQUES / CARATTERISTICHE TECNICHE

WORKING MEDIUM: AIR
ARBEITSMEDIUM: LUFT
FLUIDE D'UTILISATION: AIR
FLUIDO DI ESERCIZIO: ARIA
61/X1A
62/X1B
TERMAL RANGE OF APPLICATION:
THERMISCHER ANWENDUNGSBERREICH:
PLAGE DE TEMPERATURE EN UTILISATION:
CAMPO TERMICO DI APPLICAZIONE:
AMBIENT AIR TEMPERATURE:

UMGEBUNGSLUFTTEMPERATUR: -30 C . . . MAX. 95C
TEMPERATURE AIR AMBIANTE:
TEMPERATURA ARIA AMBIENTE:
32
FLANGE TEMPERATURE:
FLANSCHTEMPERATUR: MAX 0,5h ... 130C
-30C BIS 110C
BRIDE TEMPERATURES:
FLANGIA TEMPERATURA:
WORKING PRESSURE (SUPPLY):
BETRIEBSDRUCK (VORRAT): pe = 5,5...12 bar
PRESSION D'UTILISATION (ALIMENTATION):
PRESSIONE DI ESERCIZIO (ALIMENTAZIONE):
DEGREE OF PROTECTION ACCORDING TO IE C 529:
SCHUTZART NACH IEC 529: IP 6K9K NACH DIN 40050 T9
DEGRE DE PROTECTION SUIVANT IEC 529:
GRADO DI PROTEZIONE SECONDO IEC 529 :
VOLTAGE:
SPANNUNG:
24V -6V DC
+8V DC
TENSION :
TENSIONE:
GROUPING OF WIRES (ON THE PLUG)
STECKERBELEGUNG
GROUPEMENT DE CABLES
RAGGRUPPAMENTO DEI CAVI (SULLA CALOTTA)
HARDWARE: 446 180 101 2 DOC 610

SOFTWARE: 446 180 101 2 DOC 690 MIT SOFTWAREVERSION 201
STECKER 61/X1A
1
VPI
2
SDDK
3
CANF2-H
4
VPE1
5
VPE2
6
CANF2-L
7
SDEF
8
CANF1-H
9
SD
10 SDP
11 ADVP
12 CANF1-L
13 CANF1-L+
14 CANF1-H+
15 CANF1-T
16 VM1
17 VM2
18 VMHF1
19 VMHF2
20 VM3
M = TORQUE
M = ANZUGSMOMENT
M = COUPLE DE SERRAGE
M = COPPIA DI SERRAGGIO
SUPPLY OF ENERGY:
ENERGIEZUFLUSS: 1 ( 8mm)
APPORT D'ENERGIE:
ALIMENTAZIONE DI ENERGIA:
DELIVERY:
ARBEITSLEITUNG: 2 ( 4mm)
UTILISATION:
MANDATA:
EXHAUST:
ENTLUEFTUNG: 31> 32 , 33 16mm)
ECHAPPEMENT:
SCARICO:
ELECTRICAL CONTROL:
ELEKTRISCHER STEUERANSCHLUSS: 61, 62
COMMANDE ELECTRIQUE:
COMANDO ELETTRICO:
61/X1A
1
61/X1A
STECKER 62/X1B
1
2
VM4
3
VM3
4
5
6
VMGA2
7
ADS1
8
ADS3
9
ADS2
10 EU
11 EF2
12 ADS4
13 ADS4+
14 ADS3+
15 AU
16 VM1
17 VM2
18 ADVP
19 ADVP+
20 VMGA1
62/X1B
62/X1B
9 10 11 12 13 14 15 16 17 18 19 20
9 10 11 12 13 14 15 16 17 18 19 20
ECU STEUERELEKTRONIK
Y3
Y2
Y1
Y4
Y6
Y5
Y8
Y7
Y9
Y10
2
)(
)(
)(
)(
)(
)(
)(
)(
33
31
32
K1 - K2
SPLIT-GV
1/2-R-3/4
SELECT-WAEHLEN
2/4/R-N-1/3
SHIFT-SCHALTEN
H - L
RANGE-GP
019 067
1327 751 101 - 2003-04
2-3
ZF-AS Tronic
3
Component replacement / transmission actuator
Component replacement
74.140*
3.1
Transmission actuator
74.120*
74.130*
74.030
3.1.1 Removing transmission actuator

74.070
74.090
! DANGER
Only work on transmission actuator when ignition
is off.
Switch off ignition

74.050
74.010
CAUTION
If vehicle-specific parts (e.g. fuel pump, exhaust
pipe or steering pump) have to be removed, please
contact the vehicle manufacturer.
2
34.140
34.130
Disconnect electric plug connections from

transmission actuator.
! DANGER
Protective glasses should be worn when removing
compressed air line from transmission actuator.
Compressed air will escape. Risk of injury from
particles of dirt.
Remove compressed air line from pressure

limitation valve of transmission actuator.
Remove breather (74.120) and/or bracket piece

(74.140) and cannon socket (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 751 101 - 2003-04
74.050
12.090
12.080
06.050
06.040
06.080
Loctite
262
* depending on parts list
3-1
015166
ZF-AS Tronic
CAUTION
The rubber gaskets (/170) may fall into transmission housing.
Remove compression springs (06.050; 34.140

and 12.090) and detent pins (06.040; 34.130
and 12.080). Remove the two cylindrical pins
(74.050) if damaged.
Remove gasket (74.010) and clean sealing faces

on transmission housing and transmission actuator.
/170
Take transmission actuator (74.030) off transmission housing and note down dimensions
a and b for subsequent installation.
a
018774
NOTE
There is a transmission actuator kit. This con
sists of transmission actuator (74.030), gasket
(74.010) and breather (74.120).
74.140*
Remove ball pin (06.080) if damaged.
74.090
74.120*
74.130*
74.030
74.070
74.050
74.010
34.140
34.130
74.050
12.090
12.080
06.050
06.040
06.080
Loctite
262
1327 751 101 - 2003-04
3-2
015166
ZF-AS Tronic
3.1.2 Fitting
If the ball pin is replaced, spray thread of ball
pin (06.080) with Loctite no. 262. Tighten ball
pin to 23 Nm.
On transmission actuator, move piston rod (4)
into central position (Neutral). The correct
position is reached if slight resistance can be
felt when removing the piston rod (4).
Transfer dimensions a and b from the

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

line one another (flush). Ensure that rubber gaskets (/170) are used on transmission actuator.
/170
018774
NOTE
Piston rod (3)
Piston rod (4)
Piston rod (5)
= shifts splinter group (GV)

= shifts basic transmission
= shifts range change
group (GP)
Selection gate (6) = shifts shift gate
NOTE
With 12-speed version, do not slide central
selector rail too far into transmission otherwise
selection finger may fall into transmission.
Alternative: If dimensions a and b can no longer
be determined, the transmission actuator can be fitted
using the setting aid (34) 1X56 138 244.. For in-house
production following sketch, refer to special tools. On
request, tool 1X56 138 244 can also be supplied by
ZF.
Adjust piston rods (3, 4 and 5) of transmission actuator so that they are in contact with the setting aid (34).
Move GV and GP selector rails in transmission
towards output. Move central selector rail into neutral
position. Selection gate (6) and piston rod (4) must be
in line with one another (flush). Ensure that rubber
gaskets (/170) are used on transmission actuator.
017908
7
34
017907
1327 751 101 - 2003-04
3-3
ZF-AS Tronic
5
Place new gasket (74.010) on transmission

housing.
74.140*
74.120*
74.130*
Insert detent pins (06.040; 34.130 and 12.080)

and compression springs (06.050; 34.140 and
12.090).
74.030
74.070
74.090
NOTE
The compression springs (06.050; 34.140 and
12.090) must be of the same length (approx.
50 mm). If variances are found, replace compression springs.
7
74.050
Attach transmission actuator (74.030), in so

doing piston rods of transmission actuator must
mesh in transmission selector rails. The vertical
ball pin (06.080) meshes in the selection gate.
74.010
34.140
34.130
Tighten M8 hex bolts (74.090 and 74.070) to

23 Nm.
74.050
12.090
12.080
06.050
06.040
06.080
Depending on parts list:

Tighten canon socket (74.130) to 18 Nm and
secure bracket piece (74.140) and/or tighten
breather (74.120) to 10 Nm
CAUTION
If transmission actuator is replaced, note the following.
Reprogram transmission actuator, refer to Section 3.1.5
Take vehicle parameters from removed transmission actuator or enter new parameters.
10
11
Connect air line onto pressure limitation valve

of transmission actuator.
Tightening torque 34 Nm
Reconnect wiring harness at transmission and
vehicle end otherwise function tests cannot be
undertaken.
NOTE
Fit connector with traction relief. Check for
detent.
1327 751 101 - 2003-04
Loctite
262
015166
Final check:
Has transmission actuator been reprogrammed?
Vehicle-specific parts should be refitted wherever possible. The transmission actuator can only be tested using
the diagnosis device once the engine is running and
there is a sufficient reserve of air. The system then
undertakes a number of calibration processes. This can
take up to 5 minutes. The following errors may then for
example be displayed: piston rod not attached with error
132, 134 etc. teach-in error of sensors for gear, gate, GP,
GV with ignition on.
3-4
ZF-AS Tronic
3.1.3 Dismantling transmission actuator

1
Remove both screws (/150-1).
Left upper section (/110) of pressure limitation

valve (/180) and use both straps (1) to carefully
move sideways into grooves (2). Disconnect
plug connections (7 and 8).
Remove gaskets (/150-3 and /170)
Remove gasket (/150-2) and clean sealing

faces.
/150-1
/110
74.030
3.1.4 Assembling transmission actuator

1
Insert gasket (/150-3).
Place gasket (/150-2) on lower section (/130).
Re-establish plug connections (7 and 8). Again

check that plug connection is secure.
Place upper section (/110) on lower section

(/130).
Ensure gasket (/150-2) is positioned correctly,
if necessary fix with two screws (74.090 or
74.070). Tighten both screws
(/150-1) to 9.5 Nm.
/180
/150-2
2
/150-3
/130
/170
019352
Insert gaskets (/170).
8
7
018205
1327 751 101 - 2003-04
3-5
ZF-AS Tronic
3.1.5 Programming transmission actuator

When replacing the transmission actuator and/or
upper section, customer-specific programming and/or
setting of parameters (enter EOL data) is required.
10
The table mode adapter (6008 207 003), programming device EPD1 (0501 301 068) and
corresponding PlugIN cards are needed for
programming.
When setting parameters, the EOL data is entered
into the transmission actuator electronics using the
TestmanPro and corresponding software.
CAUTION
Reprogram transmission actuator
Take vehicle parameters from removed transmission actuator or enter new parameters.
019251
3.1.6 Replacing pressure limitation valve
74.030
NOTE
Mark installation position of pressure limitation valve
(180) for subsequent fitting.
1
Remove 4 nuts (10) and take off pressure

limitation valve (/180) and O-ring (12).
/180
12
CAUTION
Do not fit O-ring (12) with grease.
2
Insert new O-ring (12), use 4 nuts to secure

pressure limitation valve (/180) to transmission
actuator (74.030). Tighten the 4 nuts (10) to
7 Nm.
1327 751 101 - 2003-04
019252
3-6
ZF-AS Tronic
Component replacement / clutch actuator
68.300
68.010
68.330 68.320
68.060
68.210*
/120
/130
68.150
68.154
/020
/030
/010
/110
68.020
68.210*
018484
3.2
Clutch actuator
Disconnect plug connection (7) from transmission actuator and (8) from output speed sensor.
Remove wiring harness from cable terminal

(68.300, 68.320 and 68.330).
Remove 4 M8 hex nuts with washers (/030) and

take off clutch actuator (68.010).
Remove 4 M8 hex bolts (68.154) and take off

cover (68.150).
Take push rod (68.210) full out of release fork

(68.060).
3.2.1 Removal
! DANGER!
Switch off ignition
Wear protective glasses when removing compressed
air line. Compressed air will escape.
Risk of injury from particles of dirt.
Once ignition has been switched off, compressed

air line should be removed from clutch actuator.
Vent clutch actuator, to do so, release screw (6).
1327 751 101 - 2003-04
NOTE
For removal and fitting of release fork, refer to
section 3.4
3-7
ZF-AS Tronic
3.2.2 Push rod

Length A of push rod (68.210), depending on parts
list version:
68.210
OEM
ZF no.
Length in mm
DAF
1328 302 033
119.1
RVI
1328 368 008
123.1
Hyundai, KIA
1314 268 002
124
MAN TGA
1328 368 003
127.1
Meritor
1328 368 004
133.6
Meritor
1328 368 009
144.9
018485
Adjustable push rod e.g. IVECO

ZF-no.
Push rod (68.210) cpl.
(with variable adjustment)
1314 268 002
Ball pins (/110)
1314 368 008
Push rod (/120)
1314 368 004
Hex nut (/130)
0637 002 051
68.210
/110
Loosen hex nut (/130)
2.
Screw ball pins (/110) to dimension required.
3.
Tighten hex nut (/130) to 52 Nm.
1327 751 101 - 2003-04
/120
Set push rod to set dimension A.

1.
/130
019622
3-8
ZF-AS Tronic
Component replacement
6
68.210
68.020
68.060
B
019 357
3.2.3 IVECO push rod setting
Calculate from dimension C:

Dimension B + 33 mm = dimension C
The old push rod dimensions are used if only the clutch
actuator is replaced.
Example:
Dimension B = 57 mm
If driver disc or pressure plate is replaced, push rod

(68.210) has to be reset.
57 mm + 33 mm = 90 mm (dimension C)
CAUTION
If working on vehicles with an AS Tronic transmission, it is not the wear dimension which is set, as is
usually the case, but the release travel. If not set correctly, the pressure plate is damaged.
Insert push rod (68.210) in clutch actuator

(68.020). Loosen screw (6) on clutch actuator
(68.020) until cylinder moves out.
Measure dimension C between ball head of
push rod and contact face of clutch actuator.
Set push rod accordingly until dimension C is
reached.
Dimension B
Push release fork (68.060) forwards and measure

dimension B.
1327 751 101 - 2003-04
Set dimension C:
3-9
ZF-AS Tronic
3.2.4 Fitting
Venting clutch actuator
1
Loosen screw (6) M12x1.5.

If seal on screw is worn, replace seal.
Push piston back.
018475
Hold down piston and tighten screw (6).
018476
6
018477
1327 751 101 - 2003-04
3-10
ZF-AS Tronic
4
Insert push rod (68.210) in pan of release fork

(68.060).
Secure clutch actuator (68.010) and 4 washers

(/020) with 4 M8 hex nuts (/030). In so doing,
ensure connections are positioned correctly and
that push rod (68.210) is seated correctly in
release fork and clutch actuator.
68.010
6
68.210*
Tightening torque
Hex nut (/030) M8 = 23 Nm
Stud bolt (/010) M8 = 10 Nm
/130
/120
/020
/030
/010
/110
68.020
68.210*
Loosen screw (6) and wait until piston is forced

out. In so doing, ensure push rod (68.210) is
seated correctly in release fork (68.060) and
clutch actuator.
Retighten screw (6) to 22 Nm.
Secure cover (68.150) using 4 M8 hex bolts

(68.154).
Tightening torque
M8 = 23 Nm
018481
CAUTION
Do not bend cable and do not tighten hard.
Avoid chafing points.
Fit connectors with traction relief and check
detent.
8
6
68.060
68.150
68.154
If damaged, replace cable terminals (68.300,

68.320 and 68.330).
018482
Press wiring harness into cable terminals.

7
10
Connect 18 or 20-pin connector (7) to

transmission actuator and connect connector (8)
to output speed sensor.
11
Connect compressed air line to clutch actuator.
68.060
68.300
68.330 68.320
018483
1327 751 101 - 2003-04
3-11
ZF-AS Tronic
3.3
Component replacement / driver disc
Replacement of driver disc

(not ZF scope of supply)
If the driver disc is replaced, note the following:

Coat spline of input shaft with grease
OLISTA LONGTIME 3EP
(ZF no. 0671 190 050).
NOTE
Avoid dirtying driver disc with grease, oil etc.
3.3.1 Fitting engine, clutch and transmission

NOTE
The release fork is fitted when the transmission
is supplied. The transmission is supplied in
Neutral or in the highest gear.
1
Fit clutch disc and pressure plate (use a mandrel

to centre pressure plate).
Slide profile of input shaft into clutch disc.
Screw transmission and engine together.
Vent clutch actuator (refer to section 3.2.3).
Push release bearing forwards (engine end) so

that clutch snaps into release bearing snap ring.
014794
WARNING
The driver disc, pressure plate and friction lining are
part of the customer specification (basic document for
drawing up parts list).
The shift program software is co-ordinated to the
characteristics of the clutch components.
Modifications to the components (from the customer
specification) will result in poor clutch
characteristics and/or component damage.
NOTE
This happens if you place a short lever through
the transmission bell housing and use this to
press the bottom end of the release fork towards
the rear (transmission end).
CAUTION
Do not damage pressure plate.
6
Insert push rod.
Close opening on transmission bell housing

(refer to section 3.2).
1327 751 101 - 2003-04
3-12
ZF-AS Tronic
3.4
Component replacement / clutch release mechanism
Clutch release mechanism
68.050
3.4.1 Removal of release fork

1
Remove 2 M12 hex bolts (68.130) from release

shaft (68.110).
Take release bearing (68.050) and release fork

(68.060) off input shaft.
68.060
018472
Take push rod (68.210) out of release fork

(68.060).
68.210
68.060
018473
Slide release shaft (68.110) out of release fork

(68.060).
68.060
/140
Dismantle release fork (68.060).

Use suitable tool to remove shaft seal (/140)
and bush (/130). Replace ball cup (/120) if damaged or worn.
/130
/110
/130
/140
68.110
/120
68.130
018474
1327 751 101 - 2003-04
3-13
ZF-AS Tronic
Component replacement / clutch release mechanism
/110
/140
/130
68.060
/140
/130
/110
68.210
/130
/140
68.110
68.050
/120
68.130
018487
3.4.2 Fitting release fork

1
Assemble release fork (68.060).

An adapter 1X56 138 215 is needed as support
for the release fork. The other adapter 1X56 138
215 is used to press both bushes (/130) flush into
the release fork (/110).
Guide release shaft (68.110) into release fork

(68.060) taking care not damage the shaft seals.
Position release bearing (68.050) on release

flange. Do not grease sliding seat between
release bearing and release flange.
Grease contact face of release bearing (68.050) to

release fork (68.060) with OLISTA LONGTIME
3EP (ZF no. 0671 190 050). Mesh release fork
(68.060) with release bearing (68.050). Ensure
push rod (68.210) correctly.
Secure release shaft (68.110) to housing I with 2

M12 hex bolts (68.130).
Tightening torque M12 = 79 Nm
NOTE
Coat the outer circumference of the shaft seals
with methylated spirits.
2
Press in both shaft seals (/140) with adapter

1X56 138 215 until firmly home.
Grease sealing lip of shaft seals (/140) with
OLISTA LONGTIME 3EP (ZF no. 0671 190 050).
1327 751 101 - 2003-04
3-14
ZF-AS Tronic
3.5
Component replacement / output flange
Output flange
3.5.1 Removal
1
2
Remove 2 hex bolts (32.550) and take off washer (32.540).
32.550
32.540
32.530
Use commercially available three-arm extractor

to extract output flange (32.510) and remove Oring (32.530).
32.510
NOTE
When extracting flange, use intermediate piece
to protect shaft.
015171
3.5.2 Fitting
1
Heat output flange (32.510) to max. 70 C and

slide onto planetary carrier spline until firmly
home. If working with Intarder version, ensure
that screws* (32.520) are inserted.
32.540
32.510
32.550
32.530
! DANGER
Only touch hot output flange if wearing protective
gloves.
Once output flange has cooled down, insert Oring (32.530) in groove between shaft and output flange.
32.520
015169
Secure washer (32.540) with 2 M12 hex bolts

(32.550).
1327 751 101 - 2003-04
3-15
ZF-AS Tronic
Component replacement / output flange
3.5.3 Removing output cover

NOTE
Sections 3.5.3 and 3.5.4 do not apply to transmission
versions with Intarders because the parts are not present.
31.080
31.050
31.030
Remove 10 M10 hex bolts (31.070) and take off

output cover (31.050).
Take off shim (31.030).
Use appropriate tool to remove shaft seal

(31.080) taking care not to damage output
cover.
31.070
Loctite
574
015170
3.5.4 Fitting output cover

1
Coat outer circumference of shaft seal (31.080)

methylated spirits and press adapter 1X56 137
124 together with ring 1X56 138 189 into output cover (31.050) until firmly home. Apply
grease to sealing lip.
Coat sealing face of output cover with Loctite

no. 574.
NOTE
Sealing faces must be clean and free of all oil
and grease.
Attach output cover (31.050) with shim

(31.030).
Tighten 10 M10 hex bolts (31.070) to

46 Nm.
1327 751 101 - 2003-04
3-16
ZF-AS Tronic
3.6
Component replacement / speed sensor, output
Speed sensor (impulse sensor), output,

depends on vehicle manufacturer
CAUTION
If the Kitas sensor is changed, parameters must be
set for the new sensor (and/or taught-in) because
otherwise there will no longer be any tacho functions.
31.260*
3.6.1 Removal
Pull out connector.
Remove impulse sensor (31.260).
014813
3.6.2 Fitting
CAUTION
Fit connector with traction relief and check
detent.
Impulse sensor may be confused with other parts,
therefore check ZF number.
1
Screw in impulse sensor (31.260).

(Setting is not required)
Tightening torque = 45 Nm
3.6.3 Connector replacement

31.260*
If a connector has to be replaced, please use the AMP

standard tool (for connection diagram, refer to parts
list).
019249
Transmission without Intarder

Impulse sensor* (DIN bayonet) length 90 mm
Version
Hall 0501 210 859
Kitas 0501 211 735
voltage supply
ZF
6.5 - 30V
vehicle end 6.5 - 9 V
Transmission with Intarder

Impulse sensor* (DIN bayonet) length 19.8 mm
Version
Hall 0501 210 855
Kitas 0501 213 668
voltage supply
ZF
6.5 - 30V
vehicle end 6.5 - 9 V
1327 751 101 - 2003-04
3-17
ZF-AS Tronic
3.7
Component replacement / neutral switch
Replacing neutral switch*
06.260*
3.7.1 Removal
1
06.250
Remove neutral switch (06.260) with seal.
3.7.2 Fitting
1
Apply some grease to tappet of neutral switch.

Screw in neutral switch (06.260) with seal.
NOTE
Pin (06.250) must be fitted.
019250
3.7.3 Connector replacement

If a connector has to be replaced, please use the AMP
standard tool (for connection diagram, refer to parts
list).
NameZF no.
Neutral switch (DIN bayonet)
Seal
Pin
0501 210 059

0634 801 062
1328 306 024
* Option (refer to parts list)
1327 751 101 - 2003-04
3-18
ZF-AS Tronic
Component replacement / Intarder
05.400*
7
1
05.440
05.110
02.180
2
02.170
05.100
02.190
05.020
05.030*
05.030*
019068
3.8
Replacing components on Intarder
CAUTION
Fit all connectors with traction relief and check
detent.
3.8.3 Solenoid valve

1
Grease O-ring (02.180) (only use a little grease)

and insert in solenoid valve (02.170) and tighten
using 2 cylindrical bolts (02.190) M8x22.
Tightening torque
M8 = 23 Nm
3.8.1 Speed sensor, output

3.8.4 Temperature sensor
1
Screw in impulse sensor (1).

3.8.2 Tacho sensor

1
Screw in temperature sensor (05.030) with seal.

Tighten drain plug (05.020) for residual coolant

to 34 Nm.
Screw in impulse sensor (2).

Tightening torque
= 45 Nm
CAUTION
Tacho sensor must be calibrated and lead sealed.
1327 751 101 - 2003-04
3-19
ZF-AS Tronic
Component replacement / Intarder
05.400*
7
1
05.440
05.110
02.180
2
02.170
05.100
02.190
05.020
05.030*
05.030*
019068
3.8.5 Removing 3/2-way valve

1
Pull connector off 3/2-way valve (05.100) and

remove air connection (7).
Remove 2 M8 hex bolts (05.110).
Take off 3/2-way valve (05.100) with O-ring (ZF
no. 0634 313 028).
3.8.6 Removing / fitting Intarder wiring harness
Remove 3 cable connectors (05.440).
Disconnect plug connectors.
Fit Intarder wiring harness

Fitting 3/2-way valve
1
Secure new O-ring (ZF no. 0634 313 028) and

3/2-way valve (05.100) with 2 M8 hex bolts
(05.110).
Fit connector with traction relief. Ensure connector snaps in.
Secure wiring harness (05.400) to Intarder using

3 cable connectors (05.440).
Connect up air connection (7).

Tightening torque:
Union screw
M16X1.5 = 45 Nm
1327 751 101 - 2003-04
3-20
ZF-AS Tronic
3.9
Additional cooling connection
Remove screw plugs (01.030 and 01.040).
Component replacement / additional cooling
01.030
01.040
Insert O-rings (47.020 and 47.030) and union

screws (47.050 and 47.060) in valve block
(41.010).
018479
47.030
47.020
47.010
47.060
47.050
Screw union screws (47.050 and 47.060) into

transmission housing and tighten to 60 Nm.
018478
47.050
47.010
47.030
47.050 47.060 47.020
47.060
018480
1327 751 101 - 2003-04
3-21
ZF-AS Tronic
Component replacement / display
3.10 Display
ZF display 0501 211 422, CAN-compatible
CAUTION
Only work on display if ignition is off.
NOTE
The display must be accessible from below.
2
3.10.1Disassembly
1
Pull connector (2) out of display.

Press on retaining clamps (see arrow) and move
display (1) up and out.
014651
3.10.2Installation
1
Slide display (1) into opening.
CAUTION
Fit connector (2) with traction relief and check
detent.
3.10.3Connection diagram
0501 211 422, refer to Annex
Plug assignment
PIN 1:
PIN 2:
PIN 3:
PIN 4:
PIN 5:
PIN 6:
PIN 7:
PIN 8:
58 (light on /off) on = GND

AD (Piezo) Imax = 200 mA
58d (light dimmed) on = VP
SD (ZF-BUS)
CAN H
VM (GND)
CAN L
VP (Batt): 9V......32V
Max. current capacity 60mA

Type of protection: at front IP54,
at rear IP30
3.10.4Connector replacement
If the connector has to be replaced, please use the
AMP standard tool.
For vehicle-specific connection diagram, refer to parts
list.
1327 751 101 - 2003-04
3-22
ZF-AS Tronic
Component replacement / Annex
Documents attached
Connector and mating connector designations
ZF standard pneumatics diagram
List of lubricants TE-ML02 1205 754 002
for current List of Lubricants, refer to: http://www.zf.com/defaultz.asp?lang=2&id=522
Drawings attached
Drawing no.
0501 210 059c
0501 210 854b
0501 211 185a
0501 211 422e
1327 600 015b
1327 600 016a
1328 600 015c
1328 600 016b
1328 600 019
6006 629 024
6006 700 579c
6006 700 586a
6029 713 016a
6029 713 021
6029 713 022
6029 713 025a
6041 622 023c
6090 601 031
6090 604 024
6091 610 003d
6091 615 007
1327 751 101 - 2003-04
Name
Installation drawing
Circuit diagram
Circuit diagram
Circuit diagram
Connection diagram
Connection diagram
Circuit diagram
Techn. information
Signal switch
Impulse sensor
Steering wheel switch
Display
12 AS ZF-Standard
12 AS with Intarder and ZF-Standard cable tip
16 AS ZF-Standard
16 AS with Intarder ZF-Standard
Clutch
Range selector
Range selector
Range selector
ZF-AS Tronic general
Central consumer, ZF-AS Tronic general
End consumer, ZF-AS Tronic general
On-board computer
ZF E module
PTO NH/1
PTO NH/4
PTO NAS/10
PTO with emergency steering pump
3-23
Component replacement /
connector and mating connector designations
ZF-AS Tronic
Connector
Use
Type
Manuf.
ZF number
Manufacturer no.
CKD no.
Protection class
X1
GS3 on-site
electronics
20-pin Bu
Kostal
6029 201 675
Conn. housing: 09432001

Bush contact: 22124472200
Gasket: 10800444521
Blind plug: 10800472632
Adapter bracket (folding part)
ZF 0501 318 143
6029 199 090
IP 67/ 69
IP 67/ 69
X1
GS3 on-site
electronics
Bus actuator
18-pin Bu
Kostal
6029 201 752

0501 317 367
Conn. housing: 09432691

Bush contact: 22124472200
Gasket: 10800444521
Blind plug: 10800472632
6029 199 125
X36
E-module
35-pin
AMP
6029 201 262
Conn. housing: 925379-1

Bracket: 928544-1
Cap: 925380-1
ISO-1481 screw
ST 2,9X9,5-F
Gasket ZF 6020 303 013
Contact bush 925590-1
6029 199 091
X21
Diagnosis
6-pin ST MNL
AMP
6029 201 121
Conn. housing 926682-3

Contact pin: 926887-1
6029 199 027
Open connector
system, no details
of protection
class
X21
Diagnosis
Mating connector
6-pin Bu MNL
AMP
6029 201 120
Conn. housing350715-1
Contact bush: 926882-3
6029 199 092
refer to
6-pin ST MNL
Range selector
14-pin Bu
J.P.T.
AMP

6029 199 042
refer to
6-pin ST MNL
6-pin Bu
J.P.T.
AMP

6029 199 109
refer to
6-pin ST MNL
4-pin St MNL
AMP

6029 199 028
refer to
6-pin ST MNL

6029 199 108
refer to
6-pin ST MNL
X2
X5
X5
X5
Display
Display
Display
8-pin Bu
AMP
6029 201 403

6029 201 367
6029 201 130
6029 201 676
A11/A14
Output sensor
4-pin BU DIN
Bay.. angled
AMP
6029 201 618
Conn. housing 1-967325-1

Cap: 965783
Bush contact: 0-929974-1
Gasket: 828920-1
Blind plug: 828922-1
6029 199 111
IP 67/ 69K
S12
Neutral switch
4-pin BU DIN
Bay.. straight
AMP
6029 201 619

Cap: 965786
Gasket: 828920-1
6029 199 088
IP 67/ 69K
S12
Neutral switch
4-pin BU DIN
Bay.. angled
AMP
6029 201 618

Cap: 965783
Gasket: 828920-1
6029 199 111
IP 67/ 69K
6029 201 336

6029 199 043
refer to
6-pin ST MNL
X17
Junction for
22-pin Bu JPT
vehicle power supply
AMP
X17 A
M. conn.
Junction for
vehicle power supply 22-pin St JPT
AMP
6029 201 354

Pin contact: 928930-5
6029 199 025
refer to
6-pin ST MNL
X18
Junction for
vehicle power supply 18-pin Bu JPT
AMP
6029 201 361

6029 199 084
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
vehicle power supply 18-pin St JPT
AMP
6029 201 365

6029 199 026
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
CAN veh. p supply
6-pin Bu JPT
AMP
6029 201 367

6029 199 109
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
CAN veh. p supply
6-pin St JPT
AMP
6029 201 366

6029 199 110
refer to
6-pin ST MNL
X19
Junction for
cab
18-pin Bu JPT
AMP
6029 201 361

6029 199 084
refer to
6-pin ST MNL
Junction for
cab
18-pin St JPT
AMP
6029 201 365

6029 199 026
refer to
6-pin ST MNL
X20 m. conn.
for X19
Connector replacement: If a connector has to be replaced, please use the AMP standard tool (for connection diagram, refer to parts list).
1327 751 101 - 2003-04
3-24
ZF-AS Tronic
Component replacement / pneumatics diagram
Example 1
Compressor
Air dryer
Four-circuit
protection
valve
5 bar overcurrent
valve
Transmission
actuator
with pressure sensor
20 litres
Non-return
valve
Clutch actuator
014885
014 885
Example 2
Compressor
Air dryer
Four-circuit
protection
valve
Transmission
actuator
with pressure sensor
20 litres
Non-return
valve
Clutch actuator
014 886
1327 751 101 - 2003-04
5 bar
overAuxiliary concurrent
sumers
valve
014886
3-25
Translation only for your information. German text is binding.
Commercial Vehicle and

Special Driveline Technology
Manual and automatic transmissions

for trucks and buses
Product groups
x
List of lubricants TE-ML 02
Lubricant classes for service fills (2)
(1)
Transmission types see page 2!
Transmissions without
ZF-Intarder
Transmissions with
ZF-Intarder
Ecolite
_
VAN + bus 1
02D / 02F(3) / 02G

alternative recommended (4):
02A / 02B / 02H
x
---
02G
alternative recommended (4):
02A / 02B / 02C / 02H
x
---
truck + bus 2
bus 3
Ecomid / Ecomid with NMV
truck + bus
_
02A / 02B / 02C / 02D /
02H / 02L
02C / 02D / 02H / 02L
02C(5)
02C(5)
x
02A(5) / 02B / 02C / 02H
02C / 02H
ASTRONiC 2
truck, bus + crane vehicle
x
02A(5) / 02H / 02L
02H / 02L
TC-Tronic
Transmission ASTRONiC 2
x
02A(5) / 02H / 02L
---
02C(5) / ATF in
accordance with TE-ML 14
---
Ecosplit / Ecosplit with NMV

New ECOSPLIT / New ECOSPLIT with NMV
Transmatic
ASTRONiC 1
truck
Torque converter lock-up clutches TC 2

x
(1)
Approved lubricant classes for models not listed here:

- Torque converter lock-up clutches (WSK) with separate oil circuit: 02C, ATF in accordance with TE-ML 14x
- Constant-mesh and synchronised transmissions for commercial vehicles: 02A / 02B / 02C / 02H
(2)
See overleaf for approved trade products, oil drain intervals and low temperature limits.
(3)
Product group Ecolite - VAN + bus 1: TE-ML 02 applies only after the transmission has reached a total of 2,500
km. This also applies to repairs.
(4)
Product group Ecolite: In moderate climate zones, shift quality is impaired if oils of the lubricant classes
02A / 02B / 02C / 02H are used.
(5) The lubricants listed overleaf and marked thus (*) may not be used.
Comments:
1.
Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 010 and
1328 765 001 must be followed.
2.
A saponified lithium mineral oil-based multigrade grease of the NLGI class 2 should be used at greasing points
(grease code KP2K-30 in accordance with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO/DIS 6743-9).
The list of lubricants TE-ML 02, Edition 01.07.2003 replaces all

previous editions. The current list can always be obtained from
all After-Sales Service points and on the Internet under
www.zf.com / Information / Technical Information.
x
Page 1 of 14
ZF Friedrichshafen AG
D-88038 Friedrichshafen
phone: + 49 7541 77 3505x
fax:
+ 49 7541 77 7319
1205 754 102g / 07.2003
Continued
ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003
Transmission classification
in accordance to product groups
x
Product groups
Transmission types
(type in bold/italic are available with ZF Intarder)
Ecolite
VAN + bus 1
S5-42, S6-36, S6-36/2, 5S200, 6S300, 5S250VO, 5S510VO,

5S640VO, 6S320VD, 6S720VO, 5S600BO, 6S300BD
truck
6S850
bus 2
6S890, 6S700BO
bus 3
S6-85, 6S1600, 6S1000BD, 6S1200BD, 6S1000BO, 6S1200BO,

6S1600BD, 6S1700BO
Ecomid / Ecomid with NMV

truck
bus
9S75, 9S109, 16S109

8S180, 8S2100BD, 8S2100BO
Ecosplit / Ecosplit with NMV

truck
8S151, 16S151, 8S181, 16S181, 16S221, 16S251
New ECOSPLIT / New ECOSPLIT with NMV

truck (7)
16S162XTD, 16S192XTD, 16S222XTD, 16S182XTO, 16S222XTO,

16S252XTO, 16S272XTO, 8S162XTD, 8S182XTO, 8S192XTD,
8S222XTO (7)
Transmatic (Ecosplit with WSK / New

Ecosplit with WSK)
16S151 + WSK, 16S221+WSK400, 16S251+WSK440, 16S1623TD +

WSK, 16S1823TO + WSK, 16S2223TD+WSK, 16S2523TO + WSK,
16S2720TO + WSK
ASTRONiC 1
truck
12AS1800, 16AS2200
ASTRONiC 2
truck (8)
12AS2301, 16AS2601; 12AS163XTD, 12AS193XTD, 12AS193XTO,

12AS213XTO, 12AS233XTO, 16AS223XTD, 16AS263XTO (8)
12AS234XTD, 12AS254XTD, 12AS254XTO, 12AS274XTO (8)
bus
10AS2301, 12AS2000B, 12AS2300B, 10AS2310B, 10AS200XBD,

10AS200XBO, 10AS230XBD, 10AS230XBO, 10AS270XBD,
10AS270XBO, 12AS2001BO, 12AS2301BO, 12AS2701BO
crane vehicle
12AS2302, 16AS2602
TC-Tronic
12TC2740TO, TC 2
x
(7) X refers to transmission version
0 = without Intarder, 1 = Intarder, 2 = NMV, 3 = 100% overrun, 4 = servoshift
(8)
X refers to transmission version

0 = without Intarder, 1 = Intarder
Page 2 of 14
1205 754 102g / 07.2003
Continued
Oil drain intervals
x
x
Product group (9)
x
Lubricant class
Transmission types see

page 2!
Operating conditions
Ecolite
- without ZF-Intarder
x
Short-distance transport
(trucks)
x
Scheduled routes
(buses)x
x
Tough operatingx
conditionstions
Ecomid / Ecosplit /
Transmatic (10) /
ASTRONiC / TC-Tronic (10)
- without ZF-Intarder
- with ZF-Intarder
Ecolite / Ecomid /
Ecosplit / ASTRONiC
- without ZF Intarder
- with ZF-Intarder
Long-distance transport
(trucks)
x
Long-distance coach
journeys (buses)
x
02A
x
02B
x
02C/02H
x
02D/02L
02F/02G
(Ecolite
only)
oil drain interval
_
_
60.000 km
120.000
1 year
km
1 year
_
120.000
km
1 year
_
240.000
km
2 years
120.000
km
1 year
_
---
---
---
90.000 km
1 year
160.000
km
1 year
---
---
x
160.000
kmx
1 year
x
300.000
kmx
2 years
160.000
km
1 year
---
Comment:
(9)
Please observe assignment product groups to approved lubricant classes on page 1!
(10) ATF in accordance with TE-ML 14 in torque converter lock-up clutches with separate oil circuit
(WSK, TC 2): 120.000 km or 1 year.
x
Low temperatures limits

x
Lubricant classes
Oil type / SAE viscosity grade
Use at oil sump

temperatures
02B / 02D / 02F / 02G / 02L
75W / 75W-80 / 75W-85 / 75W-90 / ATF
above -40C
02A / 02B / 02H
80W / 80W-85 / 80W-90
above -25C
02C
30
above -15C
20W (Transmatic only)
below -15C
Page 3 of 14
1205 754 102g / 07.2003
Continued
Lubricant class 02A

Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 (not applicable for Intarder)
x
Note:
1. In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are
used.
2. Product group ASTRONiC: The lubricants marked thus (*) may not be used.
x
Manufacturer (02A)
Trade name (02A)
ADDINOL LUBE OIL GMBH, LEUNA/D

AGIP SCHMIERTECHNIK GMBH, WRZBURG/D
ARAL AG, BOCHUM/D
AVIA MINERALL-AG, MNCHEN/D
BAYWA AG, MNCHEN/D
BLASER SWISSLUBE AG, HASLE-REGSAU/CH
BP INTERNATIONAL, PANGBOURNE, READING/GB
BUCHER AG LANGENTHAL, LANGENTHAL/CH
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D
CASTROL INTERNATIONAL, PANGBOURNE READING/GB
CEPSA LUBRICANTS S.A., MADRID/E
CHEVRONTEXACO, GHENT/B
COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE JANEIRO/BR
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F
DE OLIEBRON B.V., ZWIJNDRECHT/NL
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA
FUCHS PETROLUB AG, MANNHEIM/D
GINOUVES GEORGES SA, LA FARLEDE/F
GULF OIL INTERNATIONAL, PITTSBURG/USA
HAFA, PARIS/F
HUILES BERLIET S.A., SAINT PRIEST/F
IGOL FRANCE SA, AMIENS/F
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D
KRAFFT S.A., ANDOAIN/E
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL
LIQUI MOLY GMBH, ULM/D
MAZIVA ZAGREB D.O.O, ZAGREB/HR
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D
MOL-LUB LTD., ALMASFUZITO/H
MOTUL SA, AUBERVILLIERS CEDEX/F
NEW PROCESS AG, TBACH/CH
OEST, GEORG MINERALLWERK, FREUDENSTADT/D
OMV AG, SCHWECHAT/A
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I
PANOLIN AG, MADETSWIL/CH
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL
REPSOL LUBRICANTES, MADRID/E
S.A.E.L., MADRID/E
ADDINOL GETRIEBEL GS 80W

ADDINOL GETRIEBEL GS 80W-90
AUTOL GETRIEBEL 80W-90
ARAL GETRIEBEL EP SAE 80W
AVIA GEAR OIL MZ 80
BAYWA MEHRZWECKGETRIEBEL SAE 80
EP-GETRIEBEL 80W-100
EP-GETRIEBEL 80W-68
EP-GETRIEBEL 80W90
BP ENERGEAR EP 80W
BP ENERGEAR EP 80W-90
FRONTOL MEHRZWECKGETRIEBEL SAE 80W
MOTOREX GEAR OIL EP 80W
MOTOREX GEAR OIL EP 80W/90
CALPAM MP GEAR OIL 80W GL 4
CASTROL EP80W
CASTROL UNITRON 80W
CEPSA TRANSMISIONES 80W-90
ERTOIL TRANSMISIONES 80W-90
ERTOIL TRANSMISIONES F SAE 80
GEARTEX EP-A 80W (*)
GEARTEX EP-A 80W-90
IPIRGEROL EP 80W
GEAR A ( 80W )
TOR MULTIPURPOSE GEAR OIL SAE 80W90
ROTRA HY 80W-90
ROTRA HY DB 80W
ESSO GEAR OIL GP-D 80W
MOBILUBE GX-A 80W
TITAN GEAR MP SAE 80W
YORK 791 SAE 80W85
GULF GEAR MZ 80W
HAFA MPB SAE 80W
HRD EP 80W
HRD EP 80W-90
TRANS EPA SAE80W-85W
KOMPRESSOL-MEHRZWECK-GETRIEBEOEL SAE 80W-90
HIDROIL SAE 80W90
Q8 T 35 SAE 80 W
Q8 T 35 SAE 80W-90
LIQUI MOLY GETRIEBEL GL 4 SAE 80W
INA TRANSMOL DB 80W
INA TRANSMOL HD 80W-90
MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE 80W
MOL HYKOMOL 80W
MOTUL GEAR MB 80W
EP GEAROIL SAE 80W
OEST MEHRZWECK-GETRIEBEL SAE 80W
OEST MEHRZWECK-GETRIEBEL SAE 80W-90
OMV GEAR OIL MP SAE 80W-85
PAKELO GEAR OIL EP/FZ SAE 80W
PAKELO GEAR OIL EP/FZ SAE 80W/90
PANOLIN EP GEAR 80W
PANOLIN EP GEAR 80W/90
HIPOL 10 ZF
HIPOL SUPER GL-4 80W
HIPOL SUPER GL-4 80W-90
CS EP M SAE 80W
GULF GEAR LUBRICANT 80W-85
Page 4 of 14
Continued
SHELL & DEA OIL GMBH, HAMBURG/D

SHELL ASEOL AG, BERN 5/CH
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D
TEXACO BRASIL S.A., RIO DE JANEIRO/BR
TOTAL LUBRIFIANTS S.A., PARIS/F
UNIL S.A., SAUMUR CEDEX/F
VALVOLINE EUROPE, DORDRECHT/NL
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB
YACCO, ST PIERRE LES ELBEUF/F
Page 5 of 14
DEAGEAR EP-A SAE 80W

ASEOL GEPRESS 80W
ASEOL GEPRESS 80W-90
SHELL SPIRAX G 80W
SHELL SPIRAX MA 80W
WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEL 80
WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEL 80W-90
UNIVERSAL EP SAE 80W
ANTAR EP 80W
ANTAR EP 80W-90
FINA PONTONIC N 80W-85
FINA PONTONIC N 80W-90
TOTAL EP 80W-85
TOTAL EP 80W-90
TRANSELF EP 80W
TRANSELF EP 80W-90
UNIL OPAL GEAR EP SAE 80W85W
HIGH PERFORMANCE GEAR OIL GL-4 80W
VEEDOL MULTIGEAR SAE 80W
BVX M 100 80W85
Continued
Lubricant class 02B

Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 / 75W-80 / 75W-85 / 75W-90x
(not applicable for Intarder)
_
Note:
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are
used.x
x
Manufacturer (02B)
Trade name (02B)

ARAL AG, BOCHUM/D
ARMORINE S.A., LANESTER CEDEX/F
BAYWA AG, MNCHEN/D
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D
CALTEX (UK) LIMITED, LONDON/GB
FALCON OIL COMPANY LTD., SHARJAH/UAE
GENOL GMBH & CO., WIEN/A
HAFA, PARIS/F
MILLERS OILS LIMITED, BRIGHOUSE/GB
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D
MODRICA OIL REFINERY, MODRICA/BIH
MORRIS LUBRICANTS, SHREWSBURY/GB
OEL-BRACK AG, HUNZENSCHWIL/CH
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
ADDINOL GETRIEBEL GX 80 W 90 ML
AGIP ROTRA TRUCK GEAR S, SAE 75W-90
ARAL GETRIEBEL EP PLUS SAE 80W-90
BM 80
AVIA SYNTOGEAR FE 75W-90 EP
AVIA SYNTOGEAR FE 80W-90
BAYWA SUPER 8090 MC
BP ENERGEAR DL 80W
BP ENERGEAR DL 80W-90
BP ENERGEAR HT 80W
BP ENERGEAR HT 80W-90
ENERGEAR SHX-M SAE 75W-90
FRONTOL GETRIEBEL FE SAE 80W-90
MOTOREX UNISYNT TX
CALPAM MULTI GEAR OIL FE 80W90
CALTEX TRANSLUBE LD SAE 80W
CALTEX TRANSLUBE LD SAE 80W-90
CASTROL AGRI GEAR ULTRA
CASTROL DYNADRIVE 80W-90
CASTROL SUPERDRIVE 80W
CEPSA TRANSMISIONES EP FE+LD 75W-90
MULTIGEAR 80W-90
MULTIGEAR S 75W-90
TOR UNIGEAR 75W90 LD
ROTRA LSX 75W-90
ROTRA TRUCK GEAR 80W-90
ESSO GEAR OIL TDL 75W-90
ESSO GEAR OIL TDL 80W-90
MOBILUBE 1 SHC 75W-90
MOBILUBE S 80W-90
FALCON SUPER EP GEAR OIL 80W/90 GL-4
TITAN SUPERGEAR MC 80W-90
GENOL GEAR-SYN 80W-90
YORK 896
EUROGEAR SAE 75W-90
HRD LONGEVIA P 80W-90
HRD LONGEVIA PXD 75W-90
SYNTHEGEAR SAE75W90
Q8 GEAR OIL XG SAE 80W-90
HYPOID GETRIEBEL TDL SAE 80W-90
MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
SYNTRAN FE/MILLERS TRX SYNTH 75W/90
PENNASOL LONGLIFE GEAR GL 4 SAE 80W
PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 80W
TRANSLUBE GL-4 SAE 80W
LODEXOL SS 80W
SERVOL EP 80W/90
GEAROIL SYNTH
QUAKER STATE SUPER Q 5 SAE 80W-90
OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST SYNTH GETRIEBEL SAE 75W-90
OMV GEAR OIL XD-4 SAE 80W-85
OMV UNIGEAR S SAE 75W-90
OMV UNIGEAR SAE 80W-90
PAKELO GLOBAL GEAR CBS SAE 75W/85
PAKELO GLOBAL GEAR SA SAE 80W
PAKELO GLOBAL GEAR SA SAE 80W/85
PAKELO GLOBAL GEAR SA SAE 80W/90
PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN SUPER DUTY SYNTH 75W/90
Page 6 of 14
Continued

S.A.E.L., MADRID/E
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE
STATOIL LUBRICANTS, STOCKHOLM/S
STRUB + CO AG, REIDEN/CH
TEDEX OIL SP.Z.O.O., PIASECZNO/PL
ZELLER + GMELIN GMBH & CO., EISLINGEN/D
ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D
Page 7 of 14
PANOLIN TOPGEAR 80W/90

HIPOL EXTRA GL-4 80W-90
HIPOL EXTRA GL-5 80W-90
GULF SYTHETIC GEAR LUBRICANT 75W-90
SHARLU EP GEAR LUBE 80W/90 (GL-4)
DEAGEAR MZ 80W-90
SHELL SPIRAX GX 80W
SHELL SPIRAX GX 80W-90
SHELL SPIRAX MX 80W-90
WINTERSHALL GETRIEBEFLUID SML 80W-90
GEARWAY G4 80W
STRUB MULTIGEAR SGO 80W-90
VULCOGEAR SYNT SGX 75W-90
TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
ANTAR EPS 75W-90
ANTAR UNIVERSAL FE 80W-90
FINA PONTONIC FDL 75W-90
FINA PONTONIC MDL 80W-90
TOTAL TRANSMISSION MDL 80W-90
TOTAL TRANSMISSION RS FE 80W-90
TOTAL TRANSMISSION SYN FE 75W-90
TRANSELF SYNTHESE FE 75W-90
TRANSELF UNIVERSAL FE 80W-90
SYNPOWER GEAR OIL TDL 75W-90
VALVOLINE STX GEAR OIL GL-5 80W-90
BVX 1000
DIVINOL GEAR OIL STO SAE 80W-90
ZEPPELIN SPEZIALGETRIEBEL GL-4/GL-5 80W-90
Continued
Lubricant class 02C

Monograde engine oil of viscosity grades: SAE 30 / 40
(mineral oil-based, applicable for Intarder)x
x
Note:
1. In moderate climate zones, shift quality is impaired if viscosity grade SAE 40 is used.
2. Product group Transmatic: At ambient temperatures below -15C, engine oil of viscosity grade
SAE 20W (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL specifications or ACEA
categories A/B/E) must be used. If possible, any one of the below-mentioned commercial
products in the viscosity class SAE 20W is to be used.
3. Product group Transmatic/TC-Tronic: The lubricants marked thus (*) may not be used.
x
Manufacturer (02C)
Trade name (02C)

ARAL AG, BOCHUM/D
FUCHS LUBRICANTS (UK) PLC, HANLEY/GB
GENOL GMBH & CO., WIEN/A
INA MAZIVA RIJEKA, RIJEKA/HR
KRAFFT S.A., ANDOAIN/E
LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA
MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F
ADDINOL TURBO DIESEL MD 305 SAE 30

ADDINOL TURBO DIESEL MD 405 SAE 40 (*)
ARAL BASICTURBORAL SAE 30
AVIA SPECIAL HDC SAE 30
BLASOL 30
BLASOL 40 (*)
BP VANELLUS C3 MONO SAE 30
BP VANELLUS C3 MONO SAE 40 (*)
MOTOREX EXTRA 30
MOTOREX MULTI DF 30
CASTROL ASSURON T PLUS SAE 30
CASTROL ASSURONT PLUS SAE 40 (*)
CASTROL TROPICAL TURBO 40 ZF (*)
CRF 30
CRF 40 (*)
URSA SUPER LA 30
URSA SUPER LA 40 (*)
TITAN TXE 30
TITAN UNIVERSAL HD 30
GENOL MULTI-TURBO 30
YORK 730 SAE 30
YORK 730 SAE 40 (*)
TRANS TURBO 4 SAE30
INA GORGONELA S 30
INA SAGARTIA 30
INA SUPER 3 30
INA SUPER 5 30
MONOGRADO SUPER S-3 SAE 40 (*)
LIQUI MOLY TOURING HIGH TECH HD 40 (*)
TOURING HIGH TECH MOTOROIL SAE 30
MONOLEC GFS ENGINE OIL SAE 30
OMEGA 643 SAE 40 (*)
MEGOL MOTORENOEL HD-C3 SG SAE 30
MEGOL MOTORENOEL HD-C3 SG SAE 40 (*)
PENNASOL MOTOR OIL EXTRA C SAE 40 (*)
MONO DIESEL SAE 30
OMV TRUCK SAE 30
OMV TRUCK SAE 40 (*)
ORLY DRACO 3001 SAE 30
ORLY DRACO 3001 SAE 40 (*)
PAKELO PKO HD 4 SAE 30
PAKELO PKO HD 4 SAE 40 (*)
PANOLIN EXTRA DIESEL 30
PANOLIN EXTRA DIESEL 40 (*)
DEA CRONOS SUPER SAE 30
ASEOL MONOGRADE CF 30
ASEOL MONOGRADE CF 40 (*)
SHELL GADINIA 30
SHELL GADINIA 40 (*)
SHELL RIMULA X 30
WINTERSHALL REKORD 30
WINTERSHALL REKORD 40 (*)
DIESELWAY 30
DIESELWAY 40 (*)
Page 8 of 14
Continued

SUOMEN PETROOLI OY, HAMINA/FIN
Page 9 of 14
TURBO HD SAE 30
TEBOIL POWER D SAE 30
URSA LA 3 SAE 40 (*)
TOTAL RUBIA S 30
ALL FLEET PLUS 30
ALL FLEET PLUS 40 (*)
YACCO TRANSPRO MAS3 SAE 30
Continued
Lubricant class 02D

Gear oil of viscosity grades: SAE 75W-80 / SAE 75W-85 / 75W-90
(semi-synthetic, applicable for Intarder)x
x
Note:
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 75W-80 are
used.
x
Manufacturer (02D)
Trade name (02D)

ARAL AG, BOCHUM/D
FL ITALIA S.P.A., VILLASTELLONE/I
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL
OMV AG, SCHWECHAT/A
S.A.E.L., MADRID/E
UNIL S.A., SAUMUR CEDEX/F
AUTOL GETRIEBEL VSL-4 75W-80

ARAL GETRIEBEL SNS SAE 75W-80
MOTOREX PRISMA TF 75W/80
CEPSA TRANSMISIONES FE+LD 75W-80
MULTIGEAR MTF 75W-80W
TOR MT/LD GEAR OIL 75W80
MOBILTRANS SHC 30
MOBILUBE XHP 75W-80
TUTELA TRUCK GEARLITE SAE 75W80
TITAN CYTRAC LD 75W-80
YORK 894 75W-80
KENNOCO FLEET TRANSMISSION LUBE ED SAE 75W-80W
HRD LONGEVIA 75W-80
Q8 T 60 SAE 75W-80
INA TRANSMOL HD 75W-80
OMV GEAR OIL LDI SAE 75W-80
PAKELO GOLDENGEAR LD SAE 75W/80
PANOLIN TRANSGEAR 75W/80W
GULF INTARDER GEAR OIL 75W-80
DEAGEAR LD 75W-80
SHELL TRANSMISSION OIL ZFLD 75W-80
ANTAR LD 75W-80
FINA PONTONIC TI 75W-80
TOTAL TRANSMISSION TI 75W-80
TRANSELF LD 75W-80
GERION LD 75W80
Page 10 of 14
Continued
Lubricant class 02F

ATF in accordance with Group standard ZFN 13015 and special requirements
x
Manufacturer (02F)
Trade name (02F)

ARAL AG, BOCHUM/D
OMV AG, SCHWECHAT/A
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN
PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL
S.A.E.L., MADRID/E
ZELLER + GMELIN GMBH & CO., EISLINGEN/D
ADDINOL ATF D II D
ADDINOL ATF D III
ARAL GETRIEBEL ATF 55 F-30589
AVIA FLUID ATF 98
CALTEX ATF-HDM
CASTROL TQ DEXRON III (F-30520)
TEXTRAN PSM
TUTELA CAR GI/E
TUTELA GI/A
TITAN ATF 4000
YORK 686
HRD STARMATIC 3
ATF 420
ATF 430
Q8 AUTO 14
Q8 AUTO 15
LIQUIMATIC SUPER ATF
OMV ATF III
PANOLIN ATF DEXRON III
MERCON V ATF
VECO MATIC IID
HIPOL ATF II D
HIPOL ATF III
GULF ATF HIGH TECH
DEAFLUID 3003
WINTERSHALL ATF III
TEXAMATIC 7045E
ELFMATIC G3
FINAMATIC HP
TOTAL FLUIDE AT 42
VEEDOL ATF DEXRON III (F-30521)
YACCO ATF III
DIVINOL FLUID III F
Page 11 of 14
Continued
Lubricant class 02G

Gear oil in accordance with ZF order specification ZFB 864 (ZF number 0671 071 010)x
Viscosity grade: SAE 75W (mineral oil-based, not applicable for Intarder)x
x
Manufacturer (02G)
Trade name (02G)
MULTIGEAR MTF LT
TITAN EG 75 ZF
TITAN GEAR ZF
Page 12 of 14
Continued
Lubricant class 02H

Gear oil of viscosity grade: SAE 80W-90x
(mineral oil-based, applicable for Intarder)x
x
Manufacturer (02H)
Trade name (02H)
TUTELA TRUCK ZC 90 SAE80W-90
Page 13 of 14
Continued
Lubricant class 02L

Gear oil of viscosity grade: SAE 75W-85x
(synthetic, applicable for Intarder)x
x
Manufacturer (02L)
Trade name (02L)

BP ENERGEAR SHX 30
CASTROL SYNTRANS
VEEDOL SYNMESH
Page 14 of 14

1327 751 101a

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REPAIR MANUAL

1327 751 101a

Subject to technical modifications.

1327 751 101a

Overview of amendments ...........................................................................................................................

1327 751 101 - 2003-04

3.3 Replacement of driver disc..........................................................................................................................

1327 751 101 - 2003-04

Index Issue date

1327 751 101 - 2003-04

Overview of amendments: 1327 751 101

Service points equipped by ZF Friedrichshafen AG all

All work performed at these service points is carried out

1327 751 101 - 2003-04

Damage resulting from work performed by non-ZF staff

Companies who repair ZF units are responsible for their

Read this manual carefully before starting any tests or

To avoid injury to staff and damage to products, all

The following safety instructions appear in this

After completion of repair work and testing, skilled staff

1327 751 101 - 2003-04

Instructions for carrying out repairs

In any instances of doubt, always contact the relevant

Parts which cannot be removed without being damaged

After removing the transmission from the vehicle, clean

If rework is needed on spacer washers or shims etc.

Lube bores and grooves must be free of anti-corrosion

Carefully cover opened transmissions to prevent the

1327 751 101 - 2003-04

Instructions for carrying out repairs

e) Fill the gap between the sealing

1327 751 101 - 2003-04

Tightening torques for nuts and bolts, extract from

This standard applies to bolts as defined in DIN 912,

The bolts are tightened using a calibrated snap torque

This standard contains data on tightening torques for

Metric standard pitch thread

Metric course pitch thread

Edition: August 1991

1327 751 101 - 2003-04

Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643

The values of the screw plug tightening torques were

The tightening torques were determined for screwing

Screw plugs (DIN 908, 910, 7604)

Union screws (DIN 7643)

* DIN 7604 Form C

1327 751 101 - 2003-04

Edition: October 1995

Changing from DIN to ISO standard codes

Replacement Result of testing/measures 1)

- some can be interchanged changed to ISO 2339

- some can be interchanged changed to ISO 2338

- some can be interchanged changed to ISO 1207

- can be interchanged changed to ISO 1580

- can be interchanged changed to ISO 1234

- can be interchanged changed to ISO 7435

- cannot be interchanged documented on DIN 439-ALT

- can be interchanged changed to ISO 4766

- can be interchanged changed to ISO 7434

- cannot be interchanged documented on DIN 555-ALT

- some can be interchanged changed to ISO 4018

- some can be interchanged changed to ISO 4016