Maintenance and Diagnostics Manual MM-0150 ZF-FreedomLine Transmission Revised 06-09
Service Notes ZF-FreedomLine Transmission Maintenance and Diagnostics Manual MM-0150 USING THIS MAINTENANCE MANUAL This maintenance manual addresses maintenance, diagnostics and use issues that owners and users of ZF-FreedomLine transmissions may encounter. It is not intended as a discussion of every issue that may arise in those contexts but is illustrative of certain information that might be considered in conjunction with installation, maintenance, repair and use of the subject transmissions.
Service Notes Before You Begin To Order Information This manual provides maintenance and diagnostic instructions for ZF-FreedomLine transmissions. Before you begin procedures: Call OnTrac at 866-668-7221 to order the following publications or visit ArvinMeritor’s commercial vehicle website at www.meritorhvs.com for free downloads. (Keyword Transmissions). 1. Read and understand all instructions and procedures before you begin to service components.
Table of Contents Regulatory Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Model Numbers and Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii 12-Speed ZF-FreedomLine 16-Speed ZF-FreedomLine Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents How to Clear Inactive Fault Codes from the Instrument Panel Display Using a Steering Column-Mount Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulatory Guidance Regulatory Guidance Regulatory Guidance All persons working with, handling or exposed to the area where work on the transmission occurs, are warned to consult and comply with all applicable health, safety, medical or environmental standards and regulations governing non-asbestos fibers. References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers employed within the United States.
Model Numbers and Ratios Model Numbers and Ratios O M – Z 16 12 A – A Highest Torque in Top Two Gears 13 = 1350 lb-ft 14 = 1450 lb-ft 15 = 1550 lb-ft 16 = 1650 lb-ft ZF-FreedomLine Ratio A O = Overdrive No Letter = Direct Drive Torque Rating 13 = 1350 lb-ft 14 = 1450 lb-ft 15 = 1550 lb-ft 16 = 1650 lb-ft 16 12 = 12-Speed 16 = 16-Speed A = Fully Automated Platform Z = ZF-FreedomLine 4002082b 12-Speed ZF-FreedomLine Transmission Description Torque Rating lb-ft Model Number Overall Ratio
Torque Specifications ZF-FreedomLine Fasteners Tightening Torque Torque Specification Description Size (lb-ft) (N•m) Drain plug M24 x 1.5 44 60 Fill/Spill plug M24 x 1.5 44 60 Fill plug (optional, located on the PTO cover) M24 x 1.5 44 60 Neutral switch M20 x 1.5 33 45 Output shaft speed sensor M20 x 1.5 15 21 Air line fittings M16 x 1.5 15 21 Cooler by-pass tubes M30 x 1.5 36 50 Oil line fittings M22 x 1.
Acronyms Acronyms Referenced in Manual ABS — Anti-Lock Braking System ACC — Accessory ASR — Anti-Slip Regulation CAN — Controller Area Network CCVS — Cruise Control/Vehicle Speed EBC1 — Electronic Brake Controller #1 ECM — Engine Control Module ECU — Electronic Control Unit EEC1 — Electronic Engine Controller #1 EEC2 — Electronic Engine Controller #2 EEPROM — Electronically Erasable Programmable Read Only Memory ERC1 — Electronic Retarder Controller #1 ETC1 — Electronic Transmission Controller #1 ETC2 — Ele
Section 1 Introduction ZF-FreedomLine Automated Two-Pedal Transmission Section 1 Introduction This manual provides maintenance and service information for the ZF-FreedomLine automated two-pedal transmission. To order information on other Meritor transmission models, refer to the Service Notes page at the front of this publication. Features ZF-FreedomLine transmission models are available in 12-speed direct and overdrive, and 16-speed overdrive to meet a variety of application requirements.
Section 1 Introduction Approved Oil Lubricant Specifications for ZF-FreedomLine Transmissions WARNING Use of inappropriate oil may damage the transmission. Do not use multi-viscosity or EP (extreme pressure additive) oils. NOTE: The ZF-FreedomLine transmission is designed to be used only with 50 weight synthetic oil. NOTE: The following partial listing shows lubricants that have been approved for use with ZF-FreedomLine transmissions.
Section 1 Introduction FUNCTION Button Press and release the FUNCTION button to switch between automatic and manual mode, move into Reverse from a stop, and skip shift (manual mode only). 앫 Moving into reverse is FUNCTION button + DOWNSHIFT (pull back lever) at standstill. 앫 FUNCTION + UP/DOWNSHIFT results in a skip shift in manual mode at standstill and when driving.
Section 1 Introduction System Malfunction Warning WARNING If a system malfunction occurs, the instrument panel display illuminates “SM” for system malfunction and you may have an audible alarm depending on vehicle configuration. When this warning occurs, you may be unable to shift the transmission. Do not continue to operate the vehicle. Serious personal injury and damage to components can result. Safely move the vehicle to the side of the road and call for assistance.
Section 1 Introduction Adjust the Starting Gear WARNING This vehicle is equipped with ZF-FreedomLine automated manual transmission. The vehicle can roll backward when stopped on a hill or grade, or when the vehicle is starting from a stop on a hill or grade. Serious personal injury and damage to components can result. 1. Press and release the FUNCTION button as necessary to switch to manual mode. 2. Move the joystick FORWARD or BACKWARD. 3.
Section 1 Introduction Adjust the Starting Gear 1. 2. Move the joystick FORWARD or BACKWARD. 3. Press and release the FUNCTION button to switch back to automatic mode. Shift Into Low Reverse from Neutral at a Stop 1. Press and hold the brake pedal. 2. Press and hold the FUNCTION button. Move the joystick BACKWARD. 3. Release the FUNCTION button.
Section 2 Fault Code Diagnostics Section Fault Code 2 Diagnostics WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Test and Repair Faults 1. Retrieve the fault codes. 2. Use a Volt-Ohm meter to test the areas where the fault codes indicate that malfunctions have occurred in the system. When you work on an electrical system, the possibility of electrical shock exists, and sparks can ignite flammable substances.
Section 2 Fault Code Diagnostics Inactive Fault Codes NOTE: All inactive fault codes will steadily display for approximately 1-1/2 seconds each. Ignore fault codes that flash. When the TCU has listed all inactive fault codes, the list will repeat. Shifter FreedomLine Transmission Shifter 1.
Section 2 Fault Code Diagnostics 3. The TCU will begin to list the inactive fault codes on the instrument panel display. Active ISO Fault Codes 4. Record the fault codes. When you’re finished, turn the ignition OFF. NOTE: All active fault codes will steadily display for approximately 1-1/2 seconds each. Ignore fault codes that flash. When the TCU has listed all active fault codes, the list will repeat. 앫 To view the fault codes again: Repeat Step 1.
Section 2 Fault Code Diagnostics 7. Release up-shift button. 8. Wait 3 seconds. 9. Press up-shift button. 10. Turn ignition “OFF”. 11. Wait until all shift lever LEDs are off. 12. Release up-shift button. 13. Check that the inactive fault codes have been cleared from the instrument panel display. 앫 If the fault codes have not cleared: Repeat this procedure.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 20 SID 14 3 Fault Description Short circuit to positive of the output ACC (power conversion enable signal for ZMTEC and continuation signal for voltage doubler and voltage supply to output speed sensor #2) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 32 PID 20 33 13 2 PID 21 Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 57 SID 39 14 Fault Description ZF CAN timeout NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist. Unplug the ZMTEC only and check for 58.0 to 62.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 60 PID 3C 5 Fault Description Open circuit of the rail select position sensor NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 63 SID 3F 14 Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 152 SID 98 5 Fault Description Open circuit at the output stage to the main solenoid (Y1) NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 191 PID BF 14 Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 231 SID E7 14 Fault Description The main TCU has not received expected SAE J1939 communications From the engine ECM, body controller, or ABS ECU. This fault can occur when the message is faulty or missing. NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics SAE Fault Code Repair Instructions Repair Instructions SAE J1587 Fault Code Fault FMI PID/ SID Instrument Panel Display Fault Code 254 SID FE 14 Fault Description Main TCU fault NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 2 2 Fault Description Short circuit to ground at the output stage to the splitter direct solenoid (Y2) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 8 8 Fault Description Short circuit to ground at the output stage to the low range solenoid (Y8) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 21 15 Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 34 22 Fault Description Open circuit at the output stage to the splitter direct solenoid (Y2) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 40 28 Fault Description Open circuit at the output stage to the low range solenoid (Y8) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 52 34 Fault Description Open circuit at output stage to large disengagement clutch valve NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 66 42 Fault Description Short circuit to positive at the output stage to the splitter direct solenoid (Y2) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 72 48 Fault Description Short circuit to positive at the output stage to the low range solenoid (Y8) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 85 55 Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 94 5E Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 100 64 Fault Description Error on output speed signal 2 (the lower one) NOTE: Output shaft speed sensor #2 plugs into the ZF-FreedomLine vehicle wiring harness (the same one that is connected to the voltage doubler and ZMTEC).
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description 108 Shift lever error 6C ZF-FreedomLine shifter analog shift lever (Freightliner and Sterling vehicles only) NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 122 7A Fault Description Mechanical failure of small clutch engagement solenoid NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description 128 Oil temperature sensor fault 80 NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 133 85 Fault Description Short circuit to positive of the rail select position sensor NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 139 8B Fault Description No range change group sensor signal (open circuit) NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 149 95 Fault Description Splitter selection fault during the splitter selection procedure NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 152 98 Fault Description Rail selection fault during the rail selection procedure NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 155 9B Fault Description Main transmission gear does not engage NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 159 9F Fault Description Range position sensor signal leaves engaged position during driving NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description 166 Permanent idle signal A6 NOTE: The idle switch is built into the accelerator pedal and is wired into the engine controller, not the transmission controller or main TCU. The TCU receives the status of the idle switch over the SAE J1939 bus.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 173 AD Fault Description The main TCU has not received communication from the engine. Error on brake switch message: CCVS NOTE: The following repair instructions pertain to active faults only.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) 190 BE Fault Description EOL EEPROM parameter out of valid range NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 2 Fault Code Diagnostics ISO Fault Code Diagnostics NOTE: ISO display codes may not be available on vehicles built prior to January 2006. Repair Instructions ISO Display ISO Fault Fault Codes Identifier (J587 Display) Fault Description NOTE: The following repair instructions pertain to active faults only. For information and instructions about inactive faults, please contact OnTrac at 866-668-7221 and request a transmission specialist.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Section 3 Maintenance Step 1 For Standard Fork Applications only NOTE: The ZF-FreedomLine does not require a regular maintenance program. However, to ensure maximum performance and quality, ensuring that the release mechanism is lubricated in regular intervals is beneficial. In most cases, lubricating the parts twice per year is sufficient. In some cases, however, lubricating the parts quarterly is normal.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Section 3 Maintenance Step 3 With the clutch fork pried back, reinstall the vent plug. This will compress the return spring and eliminate the load on the fasteners. 앫 GO TO THE NEXT STEP. 4002086a Step 4 Using a 13 mm wrench, remove the four nuts that secure the clutch actuator to the transmission housing. Remove clutch actuator. 앫 GO TO THE NEXT STEP.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Step 5 Working through the clutch inspection cover, use a 19 mm socket and ratchet to remove the two fasteners that secure the release fork assembly to the transmission. 앫 GO TO THE NEXT STEP. 4005603a Step 6 Remove the clutch actuator rod from the clutch fork. 앫 GO TO THE NEXT STEP.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Step 7 For Standard Fork Applications only TWO INSIDE LATERAL SURFACES OF THE FORK TIPS TWO FORK TIPS CROSS SHAFT NOTE: This procedure is for standard fork applications only. Lightly grease the fork in six locations using Optimol Olista Longime 3 EP grease. (ONLY USE APPROVED GREASE.) NOTE: If cross shaft is reused, clean thoroughly before applying grease.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Step 8 Install the clutch actuator rod into the ball joint. 앫 GO TO THE NEXT STEP. 4002089a Step 9 Working through the clutch inspection cover, use a 19 mm socket and torque wrench to tighten the fasteners to 85 lb-ft (115 N•m). T GO TO THE NEXT STEP.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Step 10 Use a 13 mm wrench to install the clutch actuator housing onto the transmission case with four nuts and washers. 앫 GO TO THE NEXT STEP. 4002033a Step 11 Use a 13 mm socket and torque wrench to tighten the fasteners to 17 lb-ft (23 N•m). T 앫 GO TO THE NEXT STEP.
Section 3 Maintenance Release Fork Greasing Procedure (Standard and Roller Fork Applications) Step 12 Use a 13 mm socket and torque wrench to tighten the fasteners to 17 lb-ft (23 N•m). T 앫 GO TO THE NEXT STEP. 4002079a 4002079a Step 13 Charge the air system to 120 psi. 30 90 60 0 The vehicle may not start after draining the air system if transmission was in gear. Charging the system with shop air will correct this issue.
Section 3 Maintenance SAE J1939 Requirements Flowchart Notice The ZF-FreedomLine transmission actively diagnoses SAE J1939 data bus faults and reacts accordingly when the data bus or devices on the data bus, such as engine ECM, VECU (Vehicle Electronic Control Unit), and ABS, that FreedomLine depends on, are not operating properly. The ZF-FreedomLine transmission recognizes two types of SAE J1939 data bus faults, message faults and hardware faults.
Section 3 Maintenance SAE J1939 Requirements Flowchart This flowchart continues from the previous page. Check for the following active codes. A • ISO 95 • ISO 96 • ISO 97 • ISO 103 • ISO 164 • ISO 165 Check for the following active codes. • ISO 92 • ISO 197 • ISO 198 Are any of them logged and active? Yes No The issue lies with the ABS. The ABS dash light is probably lit as well. Troubleshoot the ABS paying close attention to the wheel-end speed sensors. Follow the ABS supplier's troubleshooting.
Section 3 Maintenance Electrical Requirements Flowchart Unplug the 21-pin OEM interface connector, J7. Turn the key on but do not start the engine. Disconnect the batteries. Check the DC voltage between pin A of the OEM interface connector, J7, and battery ground. Check the resistance between pin D of the OEM interface connector, J7, and the battery ground connector. No Is the resistance 0.0 to 0.5 Ohms? The issue lies within the OEM power supply circuit. Repair as necessary.
Section 3 Maintenance Electrical Requirements Flowchart This flowchart continues from previous page. With the OSS #1 disconnected, is the issue resolved? Check the DC voltage between pin B of the OEM interface connector, J7, and battery ground. Is the voltage 9.0 to 16.0 VDC? Yes Replace the output shaft speed sensor #1. No No The issue lies within the OEM power supply circuit. Repair as necessary. Reconnect the output shaft speed sensor #1. Turn the key off.
Section 3 Maintenance Electrical Requirements Step 1 Unplug the 21-pin OEM interface connector, J7. 4002016a Step 2 Disconnect the batteries. Use a disconnect switch if available. 4004150a Step 3 H X J Check the resistance between pin D of the OEM interface connector, J7, and the battery ground connector. K W B G V L A F C M U E Is the resistance 0.0-0.5 Ohms? D T 앫 YES ➞ GO TO STEP 4. N S R P 앫 NO ➞ THE ISSUE LIES WITHIN THE OEM GROUND CIRCUIT. REPAIR AS NECESSARY.
Section 3 Maintenance Electrical Requirements Step 4 H X Check the resistance between pin E of the OEM interface connector, J7, and the battery ground connector. J K W B G V L A F Is the resistance 0.0-0.5 Ohms? C M U E 앫 YES ➞ GO TO STEP 5. D N T S 앫 NO ➞ THE ISSUE LIES WITHIN THE OEM GROUND CIRCUIT. REPAIR AS NECESSARY. P R OEM INTERFACE CONNECTOR 4004164a Step 5 H X Check the resistance between pin B of the OEM interface connector, J7, and the battery power connector.
Section 3 Maintenance Electrical Requirements Step 7 NOTE: The voltage ranges referenced in the following steps are based on voltage ranges of a system with serviceable batteries. This procedure also assumes that a battery charger is not connected to the batteries. Reconnect the batteries but leave the 21-pin OEM interface connector, J7, unplugged. 4004150a Step 8 Turn the key on but do not start the engine.
Section 3 Maintenance Electrical Requirements Step 10 H X Check the DC voltage between pin B of the OEM interface connector, J7, and the battery ground connector. J K W B G V A F U E L Is the DC voltage 9.0 to 16.0 VDC? M 앫 YES ➞ GO TO STEP 11. C D T 앫 NO ➞ THE ISSUE LIES WITHIN THE OEM BATTERY POSITIVE + CIRCUIT. REPAIR AS NECESSARY.
Section 3 Maintenance Electrical Requirements Step 13 H X Check the DC voltage between pin A of the OEM interface connector, J7, and the battery ground connector. J K W B G V A F U E L Is the DC voltage 0.0 to 0.5 VDC? M 앫 YES ➞ GO TO STEP 14. C D T 앫 NO ➞ THE ISSUE LIES WITHIN THE OEM SUPPLY/IGNITION CIRCUIT. REPAIR AS NECESSARY.
Section 3 Maintenance Electrical Requirements Step 16 Reconnect the OEM interface connector, J7. 4002016a Step 17 VEHICLE Disconnect the TCU connector, J1 (this connector is located on the passenger side of the TCU). TRANSMISSION 4002006a Step 18 Check the DC voltage between pins 1, 4 and 5 of the TCU connector, J1, and the battery ground connector. 1 2 3 6 10 15 7 11 4 12 16 5 Is the DC voltage 18.0 to 32.0 VDC? 9 8 13 앫 YES ➞ GO TO STEP 19.
Section 3 Maintenance Electrical Requirements Step 19 VEHICLE Reconnect the TCU connector, J1. GO TO STEP 20. TRANSMISSION 4002006a Step 20 Disconnect the output shaft speed sensor #1 (the three wire speed sensor without convoluted tubing). 4002024a Step 21 Turn the key on but do not start the engine. With the OSS #1 disconnected, is the issue resolved except for an active ISO 99? 앫 YES ➞ REPLACE THE OUTPUT SHAFT SPEED SENSOR #1. 앫 NO 4004154a 70 ➞ GO TO STEP 22.
Section 3 Maintenance Electrical Requirements Step 22 Reconnect the output shaft speed sensor #1. 4002024a Step 23 Turn the key off. 4004154a Step 24 Disconnect the output shaft speed sensor #2, J5 (the four-wire sensor with convoluted tubing).
Section 3 Maintenance Electrical Requirements Step 25 Turn the key on but do not start the engine. 4004154a Step 26 With the output shaft speed sensor #2 disconnected, is the issue resolved except for an active ISO 100? 앫 YES ➞ REPLACE THE OUTPUT SHAFT SPEED SENSOR #2. 앫 NO ➞ GO TO STEP 27. Step 27 Check the DC voltage between pin 1 of the output shaft speed sensor #1, J5, and the battery ground connector. 2 4 3 Is the DC voltage 18.0 to 32.0 VDC? 1 앫 YES ➞ GO TO STEP 29.
Section 3 Maintenance Electrical Requirements Step 28 Reconnect the output shaft speed sensor #2, J5. The transmission’s electrical system is operating correctly. Step 29 Reconnect the output shaft speed sensor #1. 4002024a Step 30 Turn the key off.
Section 3 Maintenance Pneumatic Requirements Flowchart Measure the air pressure in the air tank that supplies the transmission air tank. Is the air pressure 100 PSI or more? Build up the system air pressure to 120 PSI. No Yes Did building up the air pressure resolve the issue? No Yes The vehicle air pressure was low. Release the truck. Verify that the air routed to the transmission air tank is run through a dryer at some point in the system, just not immediately before the transmission air tank.
Section 3 Maintenance Pneumatic Requirements Flowchart This flowchart continues from previous page. Verify that no “T” fittings are used to supply the transmission with air. Two separate lines must be routed from the transmission air tank to the transmission. Are “T” fittings used to supply the transmission with air? At what pressure does the pressure protection valve close? Yes Contact the OEM and arrange for the installation of two separate 5/8" air lines.
Section 3 Maintenance Pneumatic Requirements Step 1 Measure the air pressure in the vehicle air tanks. Is the air pressure 100 psi or more? 앫 YES ➞ GO TO STEP 3. 앫 NO ➞ GO TO STEP 2. 4004151a Step 2 Build up the air pressure to 120 psi. 30 60 0 Does this resolve the issue? 90 PSI 앫 YES ➞ RELEASE THE TRUCK. 120 150 앫 NO ➞ GO TO STEP 3. 4002090a Step 3 Measure the air pressure at the transmission using TransSoftTM. Is the air pressure 95 to 108 psi? 앫 YES ➞ GO TO STEP 4.
Section 3 Maintenance Pneumatic Requirements Step 4 Verify the presence of a 10 L (approximately) transmission air tank. Is the transmission air tank installed? 10 L Minimum Trans. Reservoir 앫 YES ➞ GO TO STEP 5. 앫 NO ➞ CONTACT THE OEM AND ARRANGE FOR THE INSTALLATION OF A TRANSMISSION AIR TANK. 4004170a Step 5 Verify that the transmission air tank is being supplied by either the wet or dry tank. Is the air supply properly routed? 앫 YES ➞ GO TO STEP 6.
Section 3 Maintenance Pneumatic Requirements Step 7 Verify that the transmission is prioritized after the air brakes but before all other air options. Is the transmission prioritized correctly? 앫 YES ➞ GO TO STEP 8. 앫 NO ➞ CONTACT THE OEM AND ARRANGE FOR THE CORRECT PRIORITIZING OF THE TRUCK’S PNEUMATIC SYSTEM. Step 8 Verify that the two supply lines running from the transmission air tank to the transmission are 5/8” OD. Are the supply line 5/8” OD? 앫 YES ➞ GO TO STEP 9.
Section 3 Maintenance Pneumatic Requirements Step 10 ONE-WAY CHECK VALVE Verify that the transmission air tank is protected with a one-way check valve. Is a one-way check valve installed? 앫 YES ➞ GO TO STEP 11. 앫 NO ➞ CONTACT THE OEM AND ARRANGE FOR THE REPLACEMENT OF THE PRESSURE PROTECTION VALVE WITH ONE THAT PERFORMS AS SUGGESTED IN THE FREEDOMLINE INSTALLATION CONSIDERATIONS. 10 L Minimum Trans.
Section 3 Maintenance No-Start Troubleshooting Flowchart Yes Is “AL” on the transmission display when the key is turned on? Charge the air system and then attempt to start the engine. Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT. No Yes Does the starter engage? Is “--” on the transmission display when the key is turned on? Yes Verify the electrical requirements. This issue was a contaminated OEM interface connector, J7. Release the vehicle.
Section 3 Maintenance No-Start Troubleshooting Flowchart B This flowchart continues from the previous page. A Is the resistance 0.0 to 0.5 Ohms? Disconnect the OEM interface connector, J7, the neutral switch connector, J2, and the ZMTEC connector, J3. No Yes With the plunger pushed in, measure the resistance across pins 1 and 2 of the neutral switch. Check the resistance between pin C1 of the ZMTEC connector, J3 and pin C of the OEM interface connector, J7. (The neutral switch must still be jumpered.
Section 3 Maintenance No-Start Troubleshooting Step 1 Is “AL” on the transmission display when the key is turned on? AL 앫 NO ➞ GO TO STEP 2. 앫 YES ➞ CHARGE THE AIR SYSTEM AND THEN ATTEMPT TO START THE ENGINE. 4004156a Step 2 __ Is “--” on the transmission display when the key is turned on? 앫 NO ➞ GO TO STEP 3. 앫 YES ➞ VERIFY THE ELECTRICAL REQUIREMENTS OF THE TRANSMISSION. 4004160a Step 3 Is “SM” on the transmission display when the key is turned on? 앫 NO sm GO TO STEP 4.
Section 3 Maintenance No-Start Troubleshooting Step 4 With the key off, disconnect the 21-pin OEM interface connector, J7. 4002016a Step 5 H J X K WARNING W B G L Before performing this step, ensure that the transmission air system is working properly and that the transmission is in neutral. V A C F M U D E N T P R S OEM INTERFACE CONNECTOR Jumper pins C and D of the OEM side of the OEM interface connector, J7. 4004162b Step 6 Attempt to bump the engine with the starter.
Section 3 Maintenance No-Start Troubleshooting Step 7 H J X K W B G L V A C Remove the jumper wire from the OEM side of the OEM interface connector, J7. F M U D E N T P S R OEM INTERFACE CONNECTOR 4004162b Step 8 H X J K W B G V Verify that the OEM interface connector, J7, is clean and that all pins are firmly held in place. L A F C M U E Use contact cleaner as necessary. D T N S R P OEM INTERFACE CONNECTOR 4001982b Step 9 Reconnect the OEM interface connector, J7.
Section 3 Maintenance No-Start Troubleshooting Step 10 Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT. Does the starter engage? 앫 NO ➞ GO TO STEP 11. 앫 YES ➞ THE ISSUE WAS A CONTAMINATED OEM INTERFACE CONNECTOR, J7. 4004152a Step 11 Disconnect the neutral switch connector, J2. Step 12 Verify that the neutral switch connector, J2, and the neutral switch are clean and that all pins are firmly held in place. Use contact cleaner as necessary.
Section 3 Maintenance No-Start Troubleshooting Step 13 Reconnect the neutral switch connector, J2. Step 14 Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT. Does the starter engage? 앫 NO ➞ GO TO STEP 15. 앫 YES ➞ THE NEUTRAL SWITCH CONNECTOR AND/OR THE NEUTRAL SWITCH WAS CONTAMINATED. 4004152a Step 15 1 4 3 2 Jumper pins 1 and 2 of the neutral pin connector, J2.
Section 3 Maintenance No-Start Troubleshooting Step 16 Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT. Does the starter engage? 앫 NO ➞ GO TO STEP 12. 앫 YES ➞ GO TO STEP 17. 4004152a Step 17 Either the neutral switch or the neutral push pin is broken. Using a 27 mm 12 point wrench or chrome 12 point socket, remove the neutral switch.
Section 3 Maintenance No-Start Troubleshooting Step 19 With the plunger of the neutral switch pushed in, measure the resistance across pins 1 and 2 of the neutral switch. 1 4 Is the circuit open? 3 2 앫 YES ➞ GO TO STEP 20. 앫 NO ➞ REPLACE THE NEUTRAL SWITCH AND INSPECT THE NEUTRAL PUSH PIN TO MAKE SURE IT’S NOT SEIZED IN THE BORE. NEUTRAL SWITCH CONNECTOR 4004179a Step 20 NEUTRAL PUSH PIN Inspect the neutral push pin in the transmission and make sure it isn’t seized.
Section 3 Maintenance No-Start Troubleshooting Step 22 Reassemble and reconnect the neutral switch and neutral push pin. Tighten the neutral switch to 37 lb-ft (50 N•m) and make sure the sealing ring is installed. T Step 23 30 90 60 0 If not already done, build up the vehicle air pressure to 120 psi using shop air. PSI 120 150 4002090a Step 24 Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT. Does the starter engage? 앫 NO ➞ GO TO STEP 25.
Section 3 Maintenance No-Start Troubleshooting Step 25 Disconnect the OEM interface connector, J7, the neutral switch connector, J2, and the ZMTEC connector, J3. 4004183a Step 26 H X J K W B G V L A F C M U E D T N S R P K1 A1 Check the resistance across pin C1 of the ZMTEC connector, J3 and pin C of the OEM interface connector, J7. (The neutral switch must still be jumpered.) Is the resistance 0.0 to 0.5 Ohms? OEM INTERFACE CONNECTOR 앫 YES ➞ GO TO STEP 27.
Section 3 Maintenance PTO Requirements Flowchart Notice The ZF-FreedomLine transmission is delivered pre-programmed to accept both a stationary PTO (for use in neutral) and a non-stationary PTO (for use in the default PTO gear only). The installation of the PTO is the responsibility of the owner. An improperly installed PTO may damage the transmission gearing, requiring a transmission replacement. The Transmission Controller Unit (TCU) actively monitors the PTO and acts accordingly.
Section 4 Wiring/Pneumatic Diagrams Section 4 Wiring/Pneumatic Diagrams Wiring/Pneumatic Diagrams Resistance Specifications Diagnostic Connector Connector Pin Assignments Diagnostic Connector Section Wiring/Pneumatic 4 Diagrams Resistance Specifications Resistance (Measured Across Pins 1 and 2) Component Not in Neutral Neutral Switch In Neutral 0.0-0.
J20 SAE J1939-CAN H SAE J1939-CAN L SAE J1939-CAN SH FUNCTION PTO 1 SWITCH PTO 1 ACKNOWLEDGE PTO 1 ENGAGE RELAY PTO 2 SWITCH PTO 2 ACKNOWLEDGE PTO 2 ENGAGE RELAY J12 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 120 J6 J9 J7 A B C A B C D E F E G B D A J H C F P R S K N M L V W X T U A B C J8 J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J1 1 2 3 4 5 6 7 8 9 10 11 12 J4 1 2 3 4 J5 1 2 3 4 J2 TRANSMISSION HARNESS GND GND ACC J1939- 24V ING DIAG CAN H +24V +24V CAN L SPEEDO J1939+ D
Section 4 Wiring/Pneumatic Diagrams ZF-FREEDOMLINE AIR SYSTEM OVERVIEW TRANSMISSION DEDICATED AIR CIRCUIT VEHICLE AIR TANKS, DRYER, COMPRESSOR, PRESSURE PROTECTION VALVES, ETC. TRANSMISSION ACTUATOR Integrated into Transmission AIR LINES AIR FITTINGS 4 3 DEDICATED TRANSMISSION AIR TANK 5 2 1 SINGLE CHECK VALVE CLUTCH ACTUATOR Integrated into Transmission Protects air in dedicated transmission air tank if brake system has leak or line to reservoir breaks.
Section 5 Removal and Installation Step 1 Section 5 and Installation Removal WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Transmission Removal Place a pan beneath the transmission drain plug. 앫 GO TO THE NEXT STEP. Step 2 WARNING When you install a fill plug and a drain plug into a transmission, first manually position the plug, and then install and tighten it by hand.
Section 5 Removal and Installation Step 4 Disconnect the air supply line from the air filter regulator. Disconnect the cooler lines as required. WARNING Use care when disconnecting the line as it still may be under pressure. 앫 GO TO THE NEXT STEP. Step 5 Use a 13 mm socket and ratchet to remove the four fasteners that secure the clutch inspection cover. 앫 GO TO THE NEXT STEP. 4002079a Step 6 Remove the clutch inspection cover. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 If the release bearing retainer clip is not visible, the starter may need to be bumped to turn clutch so that retainer clip is visible as shown in Step 7. Unsnap the release bearing retainer clip. 앫 GO TO THE NEXT STEP. Step 8 Loosen the release bearing retainer clip by prying the release fork BACKWARD. 앫 GO TO THE NEXT STEP. Step 9 Use a 13 mm socket and ratchet to install the clutch inspection cover. Tighten the fasteners to 17 lb-ft (23 N•m).
Section 5 Removal and Installation Step 10 SAE J-1939 CONNECTOR Disconnect the SAE J-1939 and the OEM connectors. 앫 GO TO THE NEXT STEP. OEM CONNECTOR Step 11 Remove the driveline. Follow the guidelines specified by both the original equipment manufacturer (OEM) and driveline manufacturer. 앫 GO TO THE NEXT STEP. Step 12 Remove the oil cooler lines if vehicle has OEM installed cooler. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 13 Remove the rear support if one is installed. 앫 GO TO THE NEXT STEP. Step 14 WARNING SAFETY STRAPS Support the transmission securely with a transmission jack and safety straps. If the transmission is not securely supported, it can fall. Serious personal injury and damage to components can result. Support the transmission with a transmission jack and safety straps. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 16 With the transmission supported by a transmission jack, remove the transmission by carefully pulling it straight back and lowering it out of the vehicle. 앫 GO TO THE NEXT STEP. Step 17 SAFETY STRAPS Roll the transmission out from under the vehicle.
Section 5 Removal and Installation Step 1 WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Installation CLOSED Install the clutch. Refer to Clutch Actuator Housing and Wiring Harness in this section. Verify that the release bearing retainer clip is snapped. 앫 GO TO THE NEXT STEP. Step 2 Inspect the release bearing and release fork assembly. Replace damaged components.
Section 5 Removal and Installation Step 4 Inspect the splines on the input shaft for wear and damage. Use an emery cloth to remove small scratches from the input shaft. 앫 GO TO THE NEXT STEP. Step 5 Inspect the end of the input shaft where the pilot bearing is installed. Use an emery cloth to remove small scratches. Replace the pilot bearing as necessary. 앫 GO TO THE NEXT STEP. Step 6 SAFETY STRAPS WARNING Support the transmission securely with a transmission jack and safety straps.
Section 5 Removal and Installation Step 7 Position the transmission so that the input shaft aligns with the pilot bearing. 앫 GO TO THE NEXT STEP. Step 8 WARNING Carefully install the transmission input shaft into the clutch disc hub. Do not force or jam the input shaft into the hub. Damage to the clutch disc or clutch housing will result. NOTE: When you install the transmission, you may have to slightly turn the input shaft. Use SPX Kent-Moore input shaft turning tool (part number J-45556).
Section 5 Removal and Installation Step 10 Use 12 fasteners to secure the transmission to the flywheel. Tighten them in a star pattern to OEM specifications. 앫 GO TO THE NEXT STEP. FASTENERS (TYPICAL) Step 11 If necessary, reinstall the rear support. Tighten the fasteners to 145 lb-ft (195 N•m). T 앫 GO TO THE NEXT STEP. Step 12 SAFETY STRAPS Remove the safety straps. Remove the transmission jack from the transmission. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 13 Use a 13 mm socket and ratchet to remove the four fasteners that secure the clutch inspection cover. 앫 GO TO THE NEXT STEP. 4002079a Step 14 Remove the clutch inspection cover. 앫 GO TO THE NEXT STEP. 4002081a Step 15 Secure the release bearing to the release bearing retainer clip by prying the release fork BACKWARD. NOTE: Clutch actuator vent plug may need to be removed to vent air from the clutch actuator.
Section 5 Removal and Installation Step 16 Use a 13 mm socket and ratchet to install the clutch inspection cover. Tighten the fasteners to 17 lb-ft (23 N•m). T 앫 GO TO THE NEXT STEP. 4002079a Step 17 Install the clutch actuator housing and connect the air supply line to the TCU air filter regulator. Refer to Clutch Actuator Housing and Wiring Harness installation instructions. 앫 GO TO THE NEXT STEP. Step 18 Connect the air supply line to the clutch actuator housing. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 19 SAE J-1939 CONNECTOR Connect the SAE J-1939 connector and the OEM connector to the transmission. 앫 GO TO THE NEXT STEP. OEM CONNECTOR 4002015b Step 20 Connect the driveshaft to the output yoke on the transmission. Install and tighten the fasteners to the vehicle manufacturer’s specifications. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 21 Use a 22 mm wrench to remove the fill plug from the transmission. Check that the oil is even with the bottom of the fill plug hole. If necessary, add an approved full-synthetic oil through the fill plug hole until the oil is even with the bottom of the fill plug hole. Manually position the fill plug and install it into the transmission by hand. Hand tighten the plug, and then use a torque wrench to tighten the fill plug to 44 lb-ft (60 N•m).
Section 5 Removal and Installation Step 23 Charge the air system to 120 psi. 30 0 The vehicle may not start after installing the transmission due to low air pressure. Charge the system using shop air if necessary. 90 60 PSI 120 150 앫 GO TO THE NEXT STEP. 4002090a Step 24 NOTE: If the display reads “CH” after the engine is started and the transmission will not engage, verify that the release bearing retainer clip is correctly installed and that the release bearing is engaged into it.
Section 5 Removal and Installation Step 1 Clutch Removal Remove the transmission. Refer to Transmission in this section. 앫 GO TO THE NEXT STEP. Step 2 WARNING Do not use an input shaft to support the clutch during removal. The clutch can fall from the input shaft, or the input shaft can damage the pilot bearing. Always use a clutch caddy or an equivalent device to prevent serious personal injury and damage to components. Support the clutch with a clutch caddy or an equivalent device.
Section 5 Removal and Installation Step 4 GUIDE PINS Install guide pins. 앫 GO TO THE NEXT STEP. Step 5 FASTENERS Remove the remaining fasteners from the clutch housing. 앫 GO TO THE NEXT STEP. Step 6 GUIDE PINS Remove the clutch by sliding it straight back and off the guide pins.
Section 5 Removal and Installation Step 1 Installation Clean the flywheel and bell housing surface. 앫 GO TO THE NEXT STEP. Step 2 Check the flywheel and centering shoulder for damage. Refer to the engine manufacturer’s service procedures, if necessary. 앫 GO TO THE NEXT STEP. Step 3 Replace the pilot bearing. Refer to the vehicle manufacturer’s procedures. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Inspect the clutch housing, disc and release bearing for damage. 앫 If the components are damaged: Call OnTrac at 866-668-7221 for assistance. 앫 GO TO THE NEXT STEP. 4005019a Step 5 GUIDE PINS Install the guide pins into the TOP fastener holes. 앫 GO TO THE NEXT STEP. Step 6 WARNING Do not use the input shaft to support the clutch during installation. The clutch can fall from the input shaft, or the input shaft can damage the pilot bearing.
Section 5 Removal and Installation Step 7 Mad ei n 5380 1 56 S CH SA any rm e G s ide ee l - 49 18 78 0 1 66 e wh NOTE: The flywheel side of the clutch disc is marked “Flywheel-Side.” Verify that the flywheel side of the clutch disc faces AWAY from the clutch housing. 앫 GO TO THE NEXT STEP. 03 Fl y MCC 6304 9 Step 8 GUIDE PINS Install the clutch housing onto the guide pins. Ensure that clutch housing is fully seated on the flywheel. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 10 FASTENERS Remove the guide pins. Install the remaining fasteners. 앫 GO TO THE NEXT STEP. Step 11 CLUTCH COVER MOUNTING TOP 2 10 11 8 3 4 7 12 9 1 PASSENGER SIDE DRIVER SIDE 6 Use a torque wrench to alternately tighten the 12 fasteners. Consult the OEM for exact tightening torque requirements. 앫 GO TO THE NEXT STEP. 5 BOTTOM 400 611 Step 12 NOTE: The alignment shaft on the clutch caddy should slide out freely. Remove the clutch caddy.
Section 5 Removal and Installation Step 13 CLOSED Check that the release bearing retainer clip is closed before you install the transmission. 앫 GO TO THE NEXT STEP. OPEN Step 14 Install the release bearing onto the transmission input shaft. Refer to Release Bearing in this section. NOTE: The transmission control unit (TCU) automatically adjusts the clutch. No further adjustment is required.
Section 5 Removal and Installation Step 1 Voltage Doubler Removal Unplug the voltage doubler connector. 앫 GO TO THE NEXT STEP. Step 2 Use a 7/16-inch socket and ratchet to remove the four fasteners. 앫 GO TO THE NEXT STEP. Step 3 Remove the voltage doubler.
Section 5 Removal and Installation Step 1 Installation Use four fasteners with flat washers and a 7/16-inch socket and ratchet to install the voltage doubler to the component mounting plate. 앫 GO TO THE NEXT STEP. Step 2 Tighten the fasteners to 12 lb-ft (16 N•m). T 앫 GO TO THE NEXT STEP. Step 3 Plug the electrical harness assembly into the voltage doubler connector.
Section 5 Removal and Installation Step 1 ZF-FreedomLine Transmission Electronic Controller (ZMTEC) Removal Use a 1/4-inch socket and ratchet to remove the ZMTEC connector. 앫 GO TO THE NEXT STEP. Step 2 Use a 7/16-inch socket and ratchet to remove the four ZMTEC fasteners. 앫 GO TO THE NEXT STEP. Step 3 Remove the controller.
Section 5 Removal and Installation Step 1 Installation Use four fasteners with flat washers and a 7/16-inch socket and ratchet to install the ZMTEC to the component mounting plate. 앫 GO TO THE NEXT STEP. Step 2 Tighten the fasteners to 12 lb-ft (16 N•m). T 앫 GO TO THE NEXT STEP. Step 3 Plug the electrical harness assembly into the ZMTEC. Tighten the 1/4-inch locking screw.
Section 5 Removal and Installation Step 1 Transmission Yoke Removal Follow the driveline manufacturer’s instructions to remove the driveshaft from the transmission yoke. 앫 GO TO THE NEXT STEP. Step 2 Use a 19 mm socket and ratchet to remove the two fasteners that secure the retaining plate to the output shaft. 앫 GO TO THE NEXT STEP. Step 3 Remove the retaining plate and O-ring. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 WARNING Do not damage plug installed in center of output shaft! Refer to the Service Notes page on the front inside cover of this manual for instructions to order this tool. Remove the yoke using an SPX Kent-Moore puller (part number J-7804-01). 앫 GO TO THE NEXT STEP. Step 5 Remove the transmission yoke.
Section 5 Removal and Installation Step 1 Installation WARNING Do not overheat the yoke. Damage to the output shaft seal can result. Heat the yoke to 175°F (79.4°C) in an oven. 앫 GO TO THE NEXT STEP. Step 2 WARNING The yoke will be hot when you install it onto the output shaft. Wear protective gloves to prevent serious personal injury. Put on protective gloves. Install the yoke onto the output shaft, until the yoke contacts the output shaft bearing. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Tighten the fasteners to 89 lb-ft (120 N•m). T 앫 GO TO THE NEXT STEP. Step 5 Install the driveshaft. Refer to the manufacturer’s instructions. Inspect for leaks.
Section 5 Removal and Installation Step 1 Output Shaft Seal Removal Remove the transmission yoke. Refer to Transmission Yoke in this section. 앫 GO TO THE NEXT STEP. Step 2 Refer to the Service Notes page on the front inside cover of this manual for instructions to order this tool. Use an SPX Kent-Moore seal remover (part number J-24171-A or equivalent) to remove the output shaft seal. Do not reuse the output shaft seal after you remove it. Install a new seal.
Section 5 Removal and Installation Step 1 Installation Clean all loose debris from the output shaft seal area. 앫 GO TO THE NEXT STEP. Step 2 Apply a thin coat of transmission oil to the inner diameter of the seal. 앫 GO TO THE NEXT STEP. Step 3 Install the output shaft seal. Use SPX Kent-Moore output shaft seal installer (part number J-45247).
Section 5 Removal and Installation Step 1 HEX-HEAD SCREW Input Shaft Seal SEAL/ GASKET Removal SHAFT SEALING RING RELEASE FLANGE 4007230a Remove the transmission: refer to Transmission Removal in this section. The release fork and bearing will need to be removed from the transmission to perform this procedure. Remove the four M8 hex-head screws and lift off the release flange. 앫 GO TO THE NEXT STEP. Step 2 If necessary, remove the seal/gasket. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 OUTPUT COVER Remove transmission yoke: reference Transmission Yoke Removal in this section. SHIM Output Cover Removal SHAFT SEALING RING HEX-HEAD SCREW 4007231b Step 2 If necessary, remove the shim. 앫 GO TO THE NEXT STEP. NOTE: The shim is no longer needed for newer transmissions since the output cover has been modified accordingly. Step 3 Use a suitable tool to remove the shaft sealing ring.
Section 5 Removal and Installation Step 1 OUTPUT COVER SHIM Installation Coat the outer circumference of the shaft sealing ring with grease. Use an appropriate driver to press the sealing ring into the output cover and ensure it is firmly seated. Slightly grease the sealing lip. SHAFT SEALING RING 앫 GO TO THE NEXT STEP. HEX-HEAD SCREW 4007231b Step 2 Coat the sealing surface of the output cover with Loctite® 574 or equivalent sealant. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 NUTS Air Filter Regulator NOTE: The repair kit contains four nuts, one O-ring and the air filter regulator. Before removing, mark the installation position of the air filter regulator for fitting later on. Removal Remove the four nuts and take off the air filter regulator. Remove the O-ring. 4007232a Step 2 Installation CAUTION O-RING Do not use grease to fit the O-ring. Step 1 Insert the new O-ring. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 TCU Top Half/Top Cover VEHICLE Removal Remove the electrical wiring harness from the TCU connector marked “vehicle”. 앫 GO TO THE NEXT STEP. TRANSMISSION 4007234a Step 2 TRANSM ISSION Remove the electrical wiring harness from the TCU connector marked “Transmission”. 앫 GO TO THE NEXT STEP. 4007235a Step 3 Remove the air fitting from the air regulator. WARNING Use caution when disconnecting the line as it still may be under pressure. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Use a 13 mm socket to remove the 15 fasteners that secure the TCU to the transmission. 앫 GO TO THE NEXT STEP. 4007237a Step 5 SCREWS UPPER SECTION Remove both screws with a T-30 Torx tool. Step 6 Raise the upper section. WARNING GASKET PROFILE SEAL Use caution when lifting upper section. Do not damage ribbon cables! 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 PLUG CONNECTION PLUG CONNECTION Disconnect the plug connections. 앫 GO TO THE NEXT STEP. 4007239a Step 8 Ensure the profile seal remains in the bottom part of the TCU. 앫 GO TO THE NEXT STEP. Step 9 Remove the gasket. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 SCREWS UPPER SECTION Installation Place the new gasket seal on the upper section. GASKET 앫 GO TO THE NEXT STEP. PROFILE SEAL LOWER SECTION 4007238a Step 2 PLUG CONNECTION PLUG CONNECTION 4007239a 134 Reconnect the plug connections. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 3 Check that the plug connections are tight and secure. 앫 GO TO THE NEXT STEP. Step 4 Place the upper section on the lower section. Ensure that the flat seal does not move. Fix the seal if necessary. 앫 GO TO THE NEXT STEP. Step 5 Install and tighten the two screws to 7.0 lb-ft (9 N폷m). T 앫 GO TO THE NEXT STEP. Step 6 Use a 13 mm socket and ratchet to secure the TCU to the transmission with 15 fasteners. Secure the wiring harness clip to the transmission.
Section 5 Removal and Installation Step 7 Install the air fitting into the air regulator. 앫 GO TO THE NEXT STEP. 4007236a Step 8 TRANSM Connect the electrical wiring harness into the TCU connector marked “Transmission”. ISSION 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation VEHICLE Step 9 Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.
Section 5 Removal and Installation Step 1 Transmission Control Unit (TCU) VEHICLE Removal Unplug the electrical wiring harness assembly from the TCU port marked “Vehicle.” 앫 GO TO THE NEXT STEP. TRANSMISSION 4002006a Step 2 TRANSM ISSION Remove the transmission wiring harness assembly from the port marked “Transmission.” 앫 GO TO THE NEXT STEP. Step 3 WARNING Use caution when disconnecting the line as it still may be under pressure. Disconnect the air supply line from the air filter regulator.
Section 5 Removal and Installation Step 4 Use a 13 mm socket and ratchet to remove the 15 fasteners that secure the TCU to the transmission. 앫 GO TO THE NEXT STEP. Step 5 WARNING Do not rotate the transmission’s three shift rails when you remove or install the transmission control unit (TCU). Damage to the transmission will result. Remove the TCU by lifting it straight UP and OUT of the transmission. WARNING Do not move or bump shift rails.
Section 5 Removal and Installation Step 1 Installation Inspect the sealing surfaces of the TCU and transmission for debris. If necessary, use a scraper to clean the surfaces. 앫 GO TO THE NEXT STEP. Step 2 DETENT SPRINGS SHIFT FINGER WARNING OUTSIDE RAIL MIDDLE SHIFT RAIL OUTSIDE RAIL Do not move the center rail forward or rearward, only rotate it such that the shift finger points straight up. Serious damage to the transmission could result.
Section 5 Removal and Installation Step 4 /170 3 2 1 Transfer measurements for the shift rails from the removed transmission actuator to piston rods a, b, and c of the new transmission actuator. Selector gate d and piston rod b must be centered with the piston and groove inline. Ensure that the profile seals (/170) on the transmission actuator are inserted.
Section 5 Removal and Installation Step 6 WARNING INSTALL DETENT SPRINGS Use care not to drop springs into the transmission. NOTE: The detent spring on the passenger side of the center shift rail is higher than the other two springs. However, the three detent springs are identical. Remove the shift module from the transmission and reinstall the three detent springs. 앫 GO TO THE NEXT STEP. Step 7 Install a new gasket on the sealing surface. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 8 Place the shift module onto the transmission. 앫 GO TO THE NEXT STEP. Step 9 WIRING HARNESS CLIP Use a 13 mm socket and ratchet to secure the TCU to the transmission with 15 fasteners. Press down the TCU while tightening fasteners. TCU must be able to touch the gasket on all sides while applying downward pressure with the hand. WARNING Do not force together by tightening the fasteners or damage to the TCU can result.
Section 5 Removal and Installation Step 11 VEHICLE Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.” 앫 GO TO THE NEXT STEP. TRANSMISSION 4002006a Step 12 TRANSM ISSION Connect the transmission wiring harness assembly to the TCU. 앫 GO TO THE NEXT STEP. Step 13 Connect the air supply line to the TCU air filter regulator. NOTE: If issues continue to occur with correctly aligning rails, go to the next step.
Section 5 Removal and Installation Shift Rail/TCU Cylinder Adjustments for Installation 63 MM 51 MM WARNING 53 MM This procedure should only be performed if pistons on the original TCU are moved or if the procedure starting on page 134 is unsuccessful. RANGE RAIL MAIN BOX RAIL SPLITTER RAIL 4007240a Adjustment of the shift rails is necessary before installing the TCU. All three shift rails (i.e., range, main box and splitter) must be adjusted to a specific position.
Section 5 Removal and Installation Step 1 Selector Cylinder WARNING CONNECTOR LOWER SECTION This procedure is to be performed only with out-of-warranty cases. During warranty period, the complete TCU must be exchanged. NOTE: The repair kit contains the selector cylinder and a profile seal. HEX-HEAD BOLTS Removal Carefully raise the tab and pull the connector off the sensor contact. 4007254a 앫 GO TO THE NEXT STEP. Step 2 Remove the three hex-head bolts. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Disassembly Lower Section of TCU Step 1 T40 TORX SCREWS WARNING This procedure is to be performed only with out-of-warranty cases. During warranty period, the complete TCU must be exchanged. NOTE: The main transmission piston is exchanged as a complete unit with separate kit. Separate seal kit for range/splitter gear shift cylinders. Remove the selector cylinder. Refer to the procedure in this section. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 5 BUSH PISTON PISTON Use a suitable tool to raise the cylinder cover slightly and remove. PISTON 앫 GO TO THE NEXT STEP. Step 6 Take the pistons and bushings out. 앫 GO TO THE NEXT STEP. CYLINDER COVER Step 7 Replace the O-rings and grooved rings on the components. 앫 GO TO THE NEXT STEP. 4007250a Step 8 Use a suitable tool to remove the seal rings and low-friction bearing bushings.
Section 5 Removal and Installation Assembly Step 1 Use a suitable tool to insert the low-friction bearings bushings flush with the bearing bore. 앫 GO TO THE NEXT STEP. Step 2 Use a suitable tool to insert the new sealing rings. NOTE: Apply Uni-Silicon GLK 112 grease to the sealing and sliding faces. 앫 GO TO THE NEXT STEP. LOW-FRICTION BEARING BRUSHING SEAL RING 4007251a Step 3 BUSH PISTON PISTON PISTON Insert new O-rings and grooved rings on the components. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 5 CYLINDER COVERS Fit the cylinder covers in the same position from which you previously removed them and secure each one with two T40 Torx screws tightening the screws to 13 lb-ft (17 N폷m). T 앫 GO TO THE NEXT STEP. 4007249a Assembly Check Step 6 The cylinder covers are numbered for sensor installation position (refer to the arrows). SENSORS Install the sensors. Refer to the procedure in this section. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Travel Sensors Engage, Splitter, Range and Select WARNING RETAINING PLATE O-RING SCREWS This procedure is to be performed only with out-of-warranty cases. During warranty period, the complete TCU must be exchanged. TRAVEL SENSOR NOTE: The repair kit contains two screws, one retaining plate, one travel sensor and one O-ring. 4007256a Removal Step 1 Clean the area around the sensors.
Section 5 Removal and Installation Step 1 Air Pressure Sensor Removal WARNING VEHICLE This procedure is to be performed only for out-of-warranty repairs. During warranty period, replace the TCU top half. Remove the electrical wire harness from the TCU connector marked “vehicle”. 앫 GO TO THE NEXT STEP. TRANSMISSION 4007234a Step 2 Remove the electrical wire harness from the TCU connector marked “Transmission”. TRANSM ISSION 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Use a 13 mm socket to remove the 15 fasteners that secure the TCU to the transmission. 앫 GO TO THE NEXT STEP. 4007237a Step 5 SCREWS UPPER SECTION Remove both screws with a T-30 Torx Tool. 앫 GO TO THE NEXT STEP. Step 6 Raise the upper section. GASKET WARNING PROFILE SEAL Use caution when lifting upper section. Do not damage ribbon cables! 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 Disconnect plug connections. 앫 GO TO THE NEXT STEP. Step 8 PLUG CONNECTION PLUG CONNECTION Ensure the profile seal remains in the bottom part of the TCU. 앫 GO TO THE NEXT STEP. Step 9 Remove the gasket. 4007239a Step 10 Remove the four locking tabs as shown. WARNING Do not damage or break studs. Remove the cover. 앫 GO TO THE NEXT STEP. Remove the locking tabs. 4007242a Step 11 Remove the two T10 Torx screws.
Section 5 Removal and Installation Step 12 Remove the old O-ring.
Section 5 Removal and Installation Step 1 Installation Inspect the sensor and ensure the O-ring is installed. Install the sensor. 앫 GO TO THE NEXT STEP. O-RING 4007245a Step 2 Install the two T-10 Torx screws. Tighten the screws to 3 lb-ft (4 N폷m). TORX SCREWS Connect the sensor ribbon connector to the circuit board. 앫 GO TO THE NEXT STEP. SENSOR CONNECTOR 4007243a Step 3 Install the four locking tabs. 앫 GO TO THE NEXT STEP. Remove the locking tabs.
Section 5 Removal and Installation Step 4 Reconnect the plug connections (7 and 8). PLUG CONNECTION PLUG CONNECTION Check that the plug connections are tight and secure. 앫 GO TO THE NEXT STEP. 4007239a Step 5 SCREWS UPPER SECTION Place the new gasket seal on the upper section. 앫 GO TO THE NEXT STEP. Step 6 Place the upper section on the lower section. Ensure that the flat seal does not move. Fix the seal if necessary. GASKET PROFILE SEAL 앫 GO TO THE NEXT STEP. Step 7 Tighten the two screws to 7.
Section 5 Removal and Installation Step 8 Use a 13 mm socket and ratchet to secure the TCU to the transmission with 15 fasteners. Secure the wiring harness clip to the transmission. Tighten the fasteners to 17 lb-ft (23 N폷m) using a star pattern. T 앫 GO TO THE NEXT STEP. 4007237a Step 9 Install the air fitting into the air regulator. 앫 GO TO THE NEXT STEP. 4007236a Step 10 TRANSM ISSION Connect the electrical wire harness into the TCU connector marked “Transmission”. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation VEHICLE Step 11 Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.
Section 5 Removal and Installation Step 1 Transmission Wiring Harness Assembly VEHICLE Removal Unplug the wiring harness assembly from the TCU port marked “Vehicle.” 앫 GO TO THE NEXT STEP. TRANSMISSION 4002006a Step 2 Unplug the voltage doubler connector. 앫 GO TO THE NEXT STEP. Step 3 Use a 1/4-inch socket and ratchet or nut driver to remove the ZMTEC connector. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Unplug the OEM connector. 앫 GO TO THE NEXT STEP. 4002016a Step 5 Unplug the output shaft speed sensor connector. 앫 GO TO THE NEXT STEP. Step 6 Unplug the Neutral switch connector. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 Remove the wiring harness from the clips.
Section 5 Removal and Installation Step 1 Installation VEHICLE Connect the wiring harness assembly to the TCU at the connector port marked “Vehicle.” 앫 GO TO THE NEXT STEP. TRANSMISSION 4002006a Step 2 Connect the wiring harness assembly to the voltage doubler connector. 앫 GO TO THE NEXT STEP. Step 3 Connect the wiring harness assembly to the ZMTEC and secure the connection by tightening the 1/4-inch screw to 7.0 lb-ft (9.5 N•m). T 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Connect the wiring harness assembly to the OEM wiring harness. 앫 GO TO THE NEXT STEP. 4002016a Step 5 Connect the wiring harness assembly to the output shaft speed sensor connector. 앫 GO TO THE NEXT STEP. Step 6 Connect the wiring harness assembly to the SAE J-1939 connector. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 Connect the wiring harness assembly to the Neutral switch connector. 앫 GO TO THE NEXT STEP. Step 8 Secure the wiring harness assembly to the transmission clips.
Section 5 Removal and Installation Step 1 Cooler By-Pass Valve Removal Place a pan underneath the transmission to collect the oil. Remove the hoses from the by-pass valve. 앫 GO TO THE NEXT STEP. BY-PASS VALVE Step 2 Use a 27 mm socket and ratchet to remove the two fasteners that secure the by-pass valve to the transmission. 앫 GO TO THE NEXT STEP. Step 3 O-RINGS Remove the by-pass valve.
Section 5 Removal and Installation Step 1 O-RINGS Installation Install the cooler by-pass valve as shown. 앫 GO TO THE NEXT STEP. Step 2 Use a 27 mm socket and ratchet to secure the by-pass valve to the transmission with the two fasteners, sealing rings and O-rings. 앫 GO TO THE NEXT STEP. Step 3 Tighten the two fasteners to 36 lb-ft (50 N•m). T 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Fasten the hoses to the by-pass valve. Using a torque wrench, tighten the oil line fitting to the cooler-bypass to 66 lb-ft (90 N•m). Tighten the cooler line to the fitting such that it does not leak.
Section 5 Removal and Installation Step 1 Neutral Switch Removal Unplug the Neutral switch connector. 앫 GO TO THE NEXT STEP. Step 2 Use a 1-1/16-inch (27 mm) box end wrench to loosen the Neutral switch. 앫 GO TO THE NEXT STEP. Step 3 Remove the Neutral switch, sealing ring and pin.
Section 5 Removal and Installation Step 1 Installation Use a 1-1/16-inch (27 mm) socket and ratchet to install the Neutral switch and tighten to 33 lb-ft (45 N•m). T 앫 GO TO THE NEXT STEP. Step 2 Connect the electrical wiring harness to the Neutral switch connector.
Section 5 Removal and Installation Step 1 Output Shaft Speed Sensor Removal NOTE: The transmission’s upper and lower output shaft speed sensors are identical and use the same removal procedure. (Removal of the UPPER output shaft speed sensor is shown in Steps 1-3.) When removing lower speed sensor, use container to capture excess oil when sensor is removed. Unplug the output shaft speed sensor connector. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 Installation NOTE: The transmissions upper and lower output shaft speed sensors are identical and use the same installation procedure (installation of the upper output shaft speed sensor is shown in Steps 1 and 2). When removing lower speed sensor, use container to capture excess oil when sensor is removed. Use a 1-1/16-inch (27 mm) socket and ratchet to install the output shaft speed sensor and tighten to 15 lb-ft (21 N•m). T 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Section 5 and Installation Removal Step 1 WARNING Always remove the clutch actuator housing BEFORE you remove the transmission, so that the transmission does not rest on the actuator housing. Damage to the transmission will result. Clutch Actuator Housing and Wiring Harness Removal Use a 17 mm socket and ratchet to remove the vent plug. 4002086a 앫 GO TO THE NEXT STEP. Step 2 Remove the transmission wiring harness assembly from the TCU port marked “Transmission.
Section 5 Removal and Installation Step 4 Remove the transmission wiring harness from the clips. 앫 GO TO THE NEXT STEP. Step 5 Remove the air supply line. 앫 GO TO THE NEXT STEP. CLUTCH ACTUATOR AIR LINE 4005602a Step 6 Use a 13 mm wrench to remove the four nuts that secure the clutch actuator housing. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 Remove the clutch actuator housing. 앫 GO TO THE NEXT STEP. Step 8 Use a 17 mm socket and ratchet to install the vent plug. Tighten the plug to 16 lb-ft (22 N•m).
Section 5 Removal and Installation Step 1 Installation Use a 17 mm wrench to remove the vent plug from the clutch actuator housing. The plug is opposite the air line connection. 앫 GO TO THE NEXT STEP. Step 2 Manually compress the air cylinder. 앫 GO TO THE NEXT STEP. Step 3 With the air cylinder compressed, install the vent plug. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Use a 13 mm wrench to install the clutch actuator housing onto the transmission with four nuts and washers. 앫 GO TO THE NEXT STEP. 4002033a Step 5 Use a torque wrench to tighten the fasteners to 17 lb-ft (23 N•m). T 앫 GO TO THE NEXT STEP. 4002051a Step 6 Remove the vent plug again. Allow the actuator to engage the push rod. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 7 Use a 17 mm wrench to install the vent plug. Use a torque wrench to tighten the vent plug to 16 lb-ft (22 N•m). T 앫 GO TO THE NEXT STEP. Step 8 TRANSM ISSION Connect the wiring harness to the TCU port marked “Transmission.” 앫 GO TO THE NEXT STEP. Step 9 Connect the wiring harness to the output shaft speed sensor connector. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 10 Secure the wiring harness to the wiring harness clips. 앫 GO TO THE NEXT STEP. Step 11 Secure the air supply line to the clutch actuator housing.
Section 5 Removal and Installation Step 1 Release Bearing Removal NOTE: YOU MUST REMOVE THE TRANSMISSION FROM THE VEHICLE TO REMOVE THE RELEASE BEARING ASSEMBLY. If the clutch actuator housing is removed: Slide the release bearing off of the input shaft past the release fork assembly. 앫 GO TO THE NEXT STEP. Step 2 If the clutch actuator housing is not removed: Remove the release fork assembly. Refer to Release Fork, Standard and Roller Fork in this section. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 1 Installation Remove the clutch actuator housing. Refer to Clutch Actuator Housing and Wiring Harness in this section. 앫 GO TO THE NEXT STEP. 4002033a Step 2 Install the release bearing onto the input shaft without removing the release fork assembly. 앫 GO TO THE NEXT STEP. Step 3 Install the clutch actuator housing onto the transmission. Refer to Clutch Actuator Housing and Wiring Harness in this section. 앫 GO TO THE NEXT STEP.
Section 5 Removal and Installation Step 4 Operate the vehicle. Check for correct operation.
ZF Friedrichshafen AG Commercial Vehicle and Special Driveline Technology D-88038 Friedrichshafen www.zf.com Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. ZF Friedrichshafen AG reserves the right to revise the information presented or discontinue the production of parts described at any time.
