REPAIR MANUAL 6 HP-26 ZF GETRIEBE GMBH SAARBRUCKEN Version 02/11/01subject fo alterations {© Copyright 2002 all nights reserved and published by ZE Getrcbe Gmbl, Ssarbricken, Deparment MKTD No part ofthis manval may be reproduced or transmitted in any form or by any mean, electronic or mechanical, including photocopying and reording, for any purpose without the express writen permission of ZF Gesrebe Gib, Searbricken Printed in GermanyContents. 14 1s 16 7 18 22 23 24 25 26 27 3a 32 33 34 35 36 37 ‘Advance Information General Illustration of transmission Power flow diagram Specifications 13.1 Screw specifications 13.1.1 Mechatronic type E 1.3.1.2 Mechatronic type M Adjusting procedure 1.4.0 Measuring clutch packs (procedure) 1.4.1 Clearance setting, brake C (nap ring) 1.42 Clearance setting, brake D (nap ring) 1.4.3 Clearance setting, clutch B (nap ring) 1.4.4 Clearance setting, cluteh A (nap ring) 1.4.5 Clearance setting, clutch E (nap ring) 1.4.6 Clearance - output (disk) 1.4.7 Clearance - input (disk) (M type only) 148 Switch setting (detent spring) Tightening torques Transmission test (test bench) Special tools Oilflow chart (Position N) (E - type) (M-type) Disassembly Transmission disassembly according to component groups Dismantling Turret (with clutches A and E) Oil supply Clutch B Brakes C and D Output shaft with parking lock Transmission casing with shift-control and parking lock Assembly ‘Transmission casing with shift control and parking lock Output shaft with parking lock and planetary gear set Brakes C and D Clutch B Turret (drive with clutches A and E) 3.5.1 Clutch E (drive) 3.5.2 Clutch A (input) Oil supply Mechatronics, oil pan and converter (Complete mechatronics, see spare parts list, technical cover sheet, item YO2) 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 1a Lil 12/1 13/1 13/1 13/1 13/1 14 14/1 14/3 14/5 14/7 1.4/9 14/il 14/13 14id 14s 1sil 16/1 17 18/1 18/1 1.8/2 2M 2/1 2.2/1 2.3/1 2.4/1 2.5/1 2.6/1 2.7/1 3.1 3.1/1 3.2/1 3.3/1 3.4/1 3.5/1 3.5/1 3.5/4 3.6/1ii cD 6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/01Advance Information These instructions contain the procedure for repair work on the complete transmission. ‘The repair instructions will only be understood sufficiently in combination with ZFS training. Neglecting this could lead to installation errors. All disassembly and assembly work is listed in chronological order. Photos and illustrations for the various applications are general in character and not binding for every individual case. Important changes and those relevant to specific applications that have to be considered during repair work are announced in Technical Circular Letters and training courses. During the repair work ELCAT regulations and specifications must be observed, Please note the following: + Seals, e.g. O-rings, shaft sealing rings, gaskets and filters must always be renewed. + During assembly, all O-rings, cylindrical rings and other sealing rings must be greased with Vaseline before mounting. + All bearings must be slightly oiled when installed. + Exchange all lining and stee! disks in transmissions with higher distance readings (> 80,000 kilometers / $0,000 miles), + After clutch / brake damage, converters, oil pipes and oil coolers must be cleaned out thoroughly and sufficiently with an appropriate cleaning agent. + After damage to brake F, if the distance reading is high (> 80,000 km / 50,000 miles), piston F must be renewed. The following requirements should be satisfied before starting the repair work + Availability of the necessary special tools otherwise assembly faults are possible Chapter 1.8 lists the complete set of special tools. + Availability of a suitable transmission test rig. For the necessary test values, please refer to the Technical Circular Letters. 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD iiiNote: In the instructions the shift control unit is considered as a complete unit, It must not be dismantled without special experience, but should be exchanged as a complete unit. Warning: The transmission is filled for life with oil. ‘An oil change is not necessary before 160 000 km or 10 years. Make sure that the transmission is delivered with the oil quantity and oil type specified in the relevant part list document (see ELCAT). Techn. KD Techn. Documentation KD Training Bach Reus Schultz iv cD 6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/011. General 1.1 Illustration of transmission 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD La1.2. Power flow diagram E 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 12/16 HP 26 © ZF Getriebe GmbH Saarbriicken 13 Specifications 1.3.1 Screw specifications 1.3.1.1 Mechatronic type E Tighten screws of the type E mechatronic in the order of the numbering (see diagram) 1203 D.. 10 Important! Specification 1068 700 152 (Tightening torque: see Chapter 1.5) 1.3.1.2Mechatronic type M Tighten screws of thetype M mechatronic in the order of the numbering (see diagram) 19203 D..010 Important! Specification 1068 700 152 (Tightening torque: see Chapter 1.5) cD 13/1198009 98011 98012 o2/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken 1.4 Adjusting procedure 1.4.0 Measuring eluteh packs (procedure) Place the two intermediate pieces 5p01 050 329/Sp01 060 329 on the ‘marked position on measuring fixture 5p01 000 330. Using the knurled screw, turn adjusting device Sp01 001 458 to the upper limit. Attach force measuring unit Sp01 000 329 to adjusting device. Fasten it with 4 knurled screws to the ‘measuring fixture using the intermediate pieces. ing a fixing pin, connect measuring plate Sp01 040 330 with the force mea- suring unit. Using the kmurled screw, clamp the clutch pack to be measured (with steel disc on the top and corrugated disc if there is one on the bottom) in the device at 200N cD 14/1Check the value on the force measuring unit's display. Then place measuring bar Sp01 060 330 on the measuring plate, put the dial gauge’s measuring base in the measuring plate’s groove on the top disc of the set, and set the dial gauge to 0 Now use the measuring bar to measure down to the base plate. Read the measurement value * Mx In each case, the X index in Myx stands for the brake/ clutch clutch packs that are put in (A, B, C, D, B). 14/2 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/0102/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken 1.4.1 Clearance setting, brake C (snap ring) Determine space requirement Eq for brake C with measuring bar 5p01 000 330. To do this, place measuring bar Sp01 000 330 on cylinder edge of brake C. Place measuring base on the topmost point on the disk supporting area at the piston and set dial gauge to “0”. Pull measuring sensor upwards, insert into snap ring groove and press against the top edge of the groove Read measured value off at dial gauge We Determine thickness M¢ of brake C clutch pack according to Chapter 1.4.0 ‘Measuring cluteh pack. 2 Mc Space requirement E¢ is determined from measured value We plus base thickness F. Ee ‘Test value P¢ is determined from space requirements Ee minus Mc. Value Pg should be between 4.37 and 5.77 mm. Testing specification 1068 700 099. Version B Select snap ring Sq with test value Pe. Calculation: Eo=We+F Po=Ec-Mc Clearance Le with $ lining disks should be between 1.38 D 1.83 mm, cD 148Example (for 1.4.1): 1.48 mm (base thickness) 29.05 mm Mc = 2549 mm 29.05 + 1.48 30.53 mm Pe = 30.53 B 25.49 14/4 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken o2/L1/0102028 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken 1.4.2 Clearance setting, brake D (nap ring) Determine space requirement Ep of brake D with depth gauge To do this, place depth gauge on oil supply sealing face, Place measuring base on lowest point of the disk support area in the housing and read off dimension © Wy, Place measuring base on cylinder support area CD in the housing and read off dimension © Wpp, ‘Measure down from piston to cylinder support area CD and read off dimension Mpg. cD 14/5Determine thickness Mpa of brake D clutch pack D D excluding final disk D according to Chapter 1.4.0 Measuring clutch pack Mpa Space requirement Epp and clutch pack thickness! test value Ppp result from: Ep © Pp Wpa- Wop Mpa *™Mpp Value Ppp should be between 26.85 D 28.65 mm. ‘Testing specification 1068 700 114 Version B Select snap ring Sp with test value Pp, Clearance Lp with 6 lining disks should ‘be between 2.11 and 2.75 mm. Example (for 1.4.2): Wpa = 247.9 mm Wpp = 214.5 mm Mpa = 23.23 mm Mpg = 43mm Ep = 247.9 2147 = 33.2 mm Pp = 23.23+43 = 27.53 mm, 33 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/016 HP 26 © ZF Getriebe GmbH Saarbriicken 14,3 Clearance setting, clutch B (snap ring) Determine space requirement Eg for clutch B with measuring bar Sp01 000 330. For this purpose, place measuring bar Sp01 000 330 on cylinder edge of clutch B, Place measuring base on highest point of disk support area at the piston and set dial gauge to “0”, Pull measuring sensor upwards, insert into snap ring groove and press against the upper edge of the groove. Read off measured value from dial gauge > Wp, Determine thickness Mg of clutch B clutch pack according to Chapter 1.4.0 ‘Measuring cluteh pack. © Mp Space requirement E¢ results from measured value We plus base thickness FER ‘Test value Pg is therefore space requirement Ey minus Mp. Value Pp should be between 4.4 and 6.2 mm. Testing specification 1068 700 098 Version B Select snap ring Sg with test value Pp, Calculation: Eg-WgtF Pp-Ep-Mp Clearance Lg with 4 lining disks should be between 1.41 and 1.86 mm. cD 147Example (for 1.4.3): 1.48 mm (base thickness) 25.8 mm -21.92 mm, 25.8 41.48 27.28 mm Pg = 27.28 21.92 1.4/8 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken o2/L1/0102/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken 1.4.4 Clearance setting, clutch A (snap ring) Determine space requirement Ey of clutch A with measuring bar Sp01 000 330. For this purpose, place measuring bar Sp01 000 330 on cylinder edge of clutch A. Place measuring base on highest point of disk support area at the piston and set dial gauge to “0”, Pull measuring sensor upwards, insert into snap ring groove and press against the upper edge of the groove. Read off measured value from dial gauge > Wy Determine thickness Ma of clutch A clutch pack according to Chapter 1.4.0 ‘Measuring eluteh pack. OM, Space requirement Eq results from measured value Wa plus base thickness FOE, ‘Test value Pq is therefore space requirement E., minus Mq. Value Pq should be between 4.58 and 6.18 mm, Testing specifications 1068 700 084 Version B Select snap ring S with test value Pq. Calculation: E,q=WatF Pas Ea-Ma Clearance L with 4 lining disks should be between 1,59 and 2.04 mm. cD 14/9Example (for 1.4.4): F 1.48 mm (base thickness) Wa = 26.15 mm Ma = -22.38mm Eq = 26.15 +148 27.63 mm Pq = 27.63 D 22.38 3.25 mm 3.4mm 5.25D3.4 1.85 mm 14/10 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken o2/L1/0101296 o2/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken 1.4.5 Clearance setting, cluteh E (snap ring) Determine space requirement Eg of clutch with measuring bar Sp01 000 330 For this purpose, place measuring bar 5p01 000 330 on cylinder edge of clutch E. Place measuring base on the highest point of the disk support area at the piston and set dial gauge to “0”. Pull measuring sensor upwards, insert into snap ring groove and press against the upper edge of the groove. Read off measured value at dial gauge © We Determine thickness Mg of clutch E clutch pack according to Chapter 1.4.0 ‘Measuring cluteh pack. Mp Space requirement Eg resultsfrom measured value Wg plus base thickness F.OER ‘Test value Pg is therefore space requirement Ex: minus Mg. ‘Value Pg should be between 3.83 and 5.83 mm. ‘Testing specification 1068 700 048 Version B. Select snap ring Sp with test value Pp. Calculation: Ep-Wp+F Pe-ER-ME Clearance Lg with 5 lining disks should be between 1,84 and 2.37 mm, cD 14/dExample (for 1.4.5): F 1.48 mm (base thickness) We = 30.27mm Mg = 27.43 mm Eg = 30.27+148 31.75 mm Pe = 31.75 27.43 4.32 mm Sp = 24mm 14/12 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken o2/L1/011.4.6 Clearance - output (disk) Screw measuring support into appropriate bore in transmission casing and place dial gauge on output shaft Press against flange and set dial gauge to “0”, Pull on flange and read off value A. Select a thinner or thicker disk if value A is outside tolerance C. Example: (for 1.4.6) A 0.15 mm c 0.15 to 0.35 mm disk o.k. 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 144131.4.7 Clearance - input (disk) Secure oil supply in casing with 2 opposite fillister head screws 10,080, (for tightening torque see Chapter 1.5) Requirements: Shim 10.090 (thickness ~ 2.6 mm, thinnest according to WTB) is in position Push measuring device Sp01 002 379 over input shaft splines and clamp with locking screw approx. 2 mm above stator shaft Set dial gauge to 0. Determine axial clearance by pressing and pulling the handle (repeat measuring process several times). ‘Target axial clearance = 0.2 - 0.4 mm at a force of 200 N (dry according to test specification1068 700 051) If there is any deviation, insert a thicker or thinner disk 02.260 as appropriate. Check axial clearance again after this. 144 cD 6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/0102/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken (M type only) 1.4.8 Switch setting (detent spring) Set locking disk with appropriate tool or ‘manually to N position (neutral). Align detent spring with centering device 5x46 002 292 and tighten detent spring in this position Tighten output side screw first. (for tightening torque see Chapter 1.5) Tighten farther by the specified angle with special tool Sw04 000 583. Remove centering device. Shift the selector shaft through all positions and remove it again (for tightening torque see Chapter 1.5) cD 14s1.5 Tightening torques No. Designation Part List» Wrench size Page Tightening Item-No. No. torque [Nm] 1 Screw plug 01.100 Hexagonal socket. 3.1/2, 12Nm (transmission housing) Size = 5 mm (1.2.Nm) 2 Machine serew 06,090 (detent spring M type) 3. Machine screw 24.120 (guide plate) 4 Screw plug M12x1.5 24.020 (torsion spring) 5 Hex bolt 06.190 (lever) 6 Machine screw 06.210 (emergency release, E type) 7 Castellated nut 14,160 (output without Helium-WDR) (output with Helium-WDR) 8 Machine screw 10,040/150 (stator shafVintermediate plate) 9) Machine screw 10,040/180 (intermediate plate/centering plate) 10 Machine serew 10.050 (stator shaft/centering plate) 11 Countersunk screw 10.080 (intermediate plate/pump) 12 Countersunk serew 10.084 (intermediate plate/pump) 13 Machine screw 27.450 (Mechatronic) 27.500 14 Machine screw 03.020 (oil pan) ww plug M18x1.5 01.140 (transmission casing) TORX - TX 27H TORX - TX 27 Hexagonal socket Size = 6 mm Hex Size= 13 mm TORX - TX 27 Socket wrench 5X46 002 456 5X46 002 456 TORX - TX 27 TORX - TX 27 TORX - TX 27 TORX - TX 27 TORX - TX 27 TORX - TX 30 TORX - TX 27 Hexagonal socket Size = 8 mm. 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 14/15 10 Nm +30; 3.1/3 (40.3 Nm +10)) 3.4 10Nm (1.0 Nm) 3.4 23.Nm (2.3 Nm) 3.5 9.5Nm (1.0 Nm) 3.5 10Nm (1.0 Nm) 32/3 80Nm (28.0 Nm) 60 Nm (£6.0 Nm) 3.63 -15Nm (1.5 Nm) 3.6/3 10Nm (1.0 Nm) 3.6/3 15m (21.5 Nm) 144 10Nm 3.6/4 (41.0 Nm) 1414 10Nm 3.6/4 (#1.0 Nm) 13/1 8Nm 3.7/3 (40,8 Nm) 3.7/4 8Nm (0,8 Nm) 3.7/4 35m (3,5 Nm) 1stNo. Designation Part List- Wrench size Page Tightening Item-No. No. torque [Nm] 16 Screw plug M16x1.5 03.010/030 Hexagonal socket. 3.7/5. 9 Nm (oil pan) Size = 8 mm (-1.0 Nm) 17 Hex bolt M8x45 97.020 3.0/5 15Nm (converter retaining bracket) Size = 13 mm (15 Nm) 18 Hex bolt M10x16 97.030 3.115 15Nm (converter retaining bracket) Size = 17 mm (1.5 Nm) 1.5/2 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/011.6 Transmission test (test bench) The following points must be checked: Correct oil level Proper oil level; observe the vehicle manufacturer's specifications and Part List Oil level too low This can result in Engine over-rewving or no power flow in curves or when starting from a stop Valve chatter due to air pockets in the oil General malfunctions Among other things, burned clutches can be the result. Oil level too high Danger of loss due to splashing, formation of foam, strong increases in temperature at high road speeds. Loss of oil via breather; among other things, burned clutches and shifting problems can result Proper engine settings Correct idle speed; follow specifications from vehicle manufacturer. Power flow, forward and reverse Correct adjustment of selector linkage or control cable; observe the vehicle manufacturer's specifications. 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 16/117 Special tools onmect Order-No,/ Application Remarks 1 5p01 000 329 identical Force gauge 4 HP 20 SHP19 5 HP 19 FL/A SMP 24 i 5 HP 24A ! [p8008 2 5p01 000 330 identical Clutch play measuring device 4uP 20 (Measuring plate: SHPI9 ~ short neck > 20 mm SHP 19 FLIA = Tong neck <20 mm 5 HP 24 cluteh disk thickness) SHP24A a. Ip8034 3 5p01 001 458 identical Pre-tension adjusting device 4HP18Q 4 HP 20 SHP19 SP 19 FLIA 5 HP 24 SHP24A, o2/i1/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cDRemarks Order-No. / Application oBIECT Sp01 002 379 Input shaft axial play ‘measuring device 5166 000 094 ‘Transmission retaining bracket 02001 identical 5x46 000 221 Assembly bracket, brake D SHP 18 02014] 17/2 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/01oBIECT Order-No,/ Application Remarks 7 5x46 000 291 identical Locking sleeve driving-in mandrel 4HP18Q 5S HP 24 5 HP24A 197306 8 5x46 000 306 identical Pump torque checking sleeve 4HP 18.Q SHPI9 lpsi3s 9 5x6 000 563 identical Disassembly/assembly fixture for complete oil supply unit SHPI8 SMP 244, 5 HP 30 lp1190 o2/i1/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cp 178Remarks Order-No, / Application identical 5x46 000 763 10 ‘Work-bench holder 4 HP 20 SHPI8 5S HP 30 9119 identical 5x46 000 917 i Mount SHP 24 SHP24A 5 HP 30 92214 identical 5x46 001 007 2 2 locating pins SHP19 SMP 19 FLIA SHP 24 SHP24A 92223 La cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/01Order-No,/ Application Remarks B 5x46 001 135 identical Bleed valve driving-in pin SMP 24 197307 a 5x46 002 456 ‘Nut wrench lo2002 15 5x46 002 558 Driving-in mandrel for needle roller bearing and pump shaft sealing ring loz003 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD LSRemarks Order-No, / Application onset 5x46 002 559 16 Driving-in mandrel for shaft sealing ring * needle roller bearing 02004] 5x46 002 560 " Driving-in mandrel for output side ball bearing 0200s| 5x46 002 561 18 Driving-in mandrel for shaft sealing ring WDR | 02006] 1.716 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/01oBIECT Order-No. / Application Remarks lo2007 lo2008 lo2009 5x46 002 563 Turret lifting device 5x46 002 566 Assembly bracket for clutch A.B,D,E ‘5x46 002 567 Driving-in mandrel for output- side shaft sealing ring 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 177Remarks Order-No, / Application onset identical 5x46 001 SOL 2 Assembly bracket for brake C SP 24 SHP24A 97312 5x46 002 569 23 Pull-out handle 2014] 5x46 002 571 4 ‘Assembly aid, clutch E snap ring 02012] L718 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/01Order-No. / Application Remarks 76046 197315 27, 28, 29 Bes lo2036 5x56 000.090 2 converter pull-out handles 5x46 001 930 Driving tool for snap ringin the gtoove of the housing 5x46 002 849 ‘Mandrel helium-shaft sealing ring 5x46 012 696 ress-in aid helium-shaft sealing ring BMW 5x46 012 798 Press-in aid helium-shaft sealing ring Jaguar 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 1.719Remarks Order-No. / Application oBIECT (M type only) 30 Sw04 000 583, Torsional measuring device, detent spring assembly 5x46 002 292 Centering device, detent spring 02026| 17/10 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/011.8 Oilflow chart (Position N) type) 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD La6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/01 cD2. Disassembly 2.1 Transmission disassembly according to component groups ‘Clamp transmission into support bracket 5166 000 094 and fasten to assembly trolley, if necessary in workbench holding device 5x46 000 763. Screw out oil drain plug /oil filler cap and drain oil eT 5) ee | i , Wrench sizes Oil drain plug = 10 mm Hexagonal socket Oil filler plug = 8 mm Hexagonal socket (01202 Remove converter bracket and take out converter using the two converter pull-out handles 5x56 000 090. (Wrench size = 13 mm) (Wrench size = 17 mm) Warning! Oil may be spilled. Do not damage converter bearings and shaft sealing ring of the pump. ‘Turn transmission by 180° Unscrew 21 machine screws holding the oil pan, remove it and pull off the O-ring seal and gasket (Wrench size = Torx -TX 27) 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 2aPull protective transport cap off socket, for wiring harness and release retaining clamp. Pull socket out of casing by hand, Unscrew serews with large head (M6) and lift off complete Mechatronics. (Wrench size = Torx - TX 40) Pull 4 sealing sleeves out of transmission casing with handle 5x46 002 569. Remove sealing sleeve from transmission casing 2.42 cD 6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/01“ . ‘Turn transmission by 90°, Completely remove oil supply unit, To do this, loosen 14 Torx screws and remove with Usit rings. (Wrench size = Torx - TX 27) Press out the oil supply unit with jack 5x46 000 563 and lift off ‘Take out the shim washer. Remove turret (input with clutches A and 5). To do this, lock lifting device 5x46 (002 563 in the input shaft with 5 mm_ mandrel. Take out the complete unit by hand. Insert turret into fixture 5x46 000 917 and remove the fixture, 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 213Remove axial needle roller bearing cage from hub of cylinder B, Warning! ‘The second angled thrust washer is located in the hub of internal disk cartier B and could be loosened during cleaning. Risk of losst Remove clutch B manually. ‘Tum transmission by 90° and loosen the 12-sided nut with wrench 5x46 002.456. Pull off the output flange, If present remove the reversing disk. 24 cD 6 HP 26 © ZF Getrieve GmbH Saarbriicken 02/11/01‘Turn transmission by 90° and lever snap || ring out of casing with a screwdriver or take it out with snap ring pliers. Lift off clutch C. ‘Take out the angle plate and sun gear. Remove planet carrier with complete clutch pack D. Remove final disk from transmission casing. Remove complete clutch pack D from planet carrier. Remove thrust plates and sun gears 2 +3 from planet carrier. Lift clip bearings from planet carrier and sun gear 3 03001 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 2SLift thrust washer off planet carrier hub. Take out ring gear with output shaft. Remove output axial clearance adjusting disk. 2.16 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/0101221 (01222 01223 o2/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken Dismantling 2.2 Turret (with clutches A and E) Put turret with input shaft in mount 5x46 000 917. Unolip the angled disk. fake out the snap ring and remove internal disk carrier B. ‘Take out disk cartier A and lever axial needle roller bearing out of intermediate shaft with a long seriber Lift off intermediate shaft with internal disk carrier E, Lever out axial needle roller bearing, ‘Then turn cluster by 180° and insert it into the fixture again cD 22/1Pull clutch A off clutch E / input shat. Note: Drive shaft is splined to clutch E. Rebound clutch A snap ring and withdraw complete clutch pack, Lever snap ring out of planet carrier and take planet carrier out of cylinder A. Withdraw snap ring and sun gear from planet carrier and lever out axial needle roller bearing cage. 2.212 cD 6 HP 26 © ZF Getriebe GmbH Saarbriicken 02/11/01Press down cup spring in the mandrel press with assembly bracket 5x46 002 566 and remove snap ring with suitable pliers. Take out planet carrier and cup spring. Take the O-ring seal off the planet carrier. Place cylinder A on top of the oil supply | and press out piston with compressed air. Pull 2 O-ring seals off piston A. Remove cylinder A from oil supply 01229 Pull out clutch E snap ring and withdraw complete clutch pack of clutch E. 02/11/01 6 HP 26 © ZF Getriebe GmbH Saarbriicken cD 2.2/3