5871 133 002 - ZF - REVERSING GEARBOX 4 WG-98 TSC + TB92-I4 (Telescopic Handler Side Mount Compact + Transfer Box) Workshop Manual

Ordering No.
: 5871 133 002
ZF - REVERSING GEARBOX
4 WG-98 TSC + TB92-I4
(Telescopic Handler Side Mount Compact + Transfer Box)
ZF Passau GmbH
Donaustr. 25 - 71
D- 94 034 Passau
Edition: 2003/03
REPAIR MANUAL
for
ZF - REVERSING GEARBOX
4 WG-98 TSC +TB92-I4
IMPORTANT REFERENCE:
The extreme variety of ZF-units requires that the disassembly- and assembly instructions are limited
to a frequently sold ZF-series unit. The further technical development of the ZF-units as well as
extension and execution options can require deviating operations which can be performed by
qualified expert staff without any problem with the aid of the perspective representations in the
respective spare parts lists.
The present disassembly and assembly instructions represent the construction state of a ZF-series
unit at the time of the preparation of these instructions.
Information regarding description, operation and maintenance may be taken from the respective
operating instructions (ZF ordering-No.: 5872 135 002).
The ZF Passau GmbH reserves the right to substitute the present disassembly- and assembly
instructions at any time by a successor edition without special notice. Upon request, the ZF Passau
will inform you on the actual and binding edition.
----------------------------------------------------------------------------------------------------------
ATTENTION:
For the installation and starting up of the unit, observe the instructions
of the vehicle manufacturer!
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Division: ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite !
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous réserve de modifications techniques !
1. Auflage / 1st edition / 1ère édition
Off-Road Driveline
Workshop Manual Technology and Axle
Systems Division
PREFACE
This documentation has been developed for skilled staff trained by the Zahnradfabrik Passau for the repair
and maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
After-Sales Service
5871 133 002 0/1

Off-Road Driveline
Systems Division
GENERAL
The Service Manual covers all works required for the disassembly and the pertaining assembly.
When repairing the gearbox, ensure utmost cleanliness and that the works are carried out in an expert-like
manner. The gearbox should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races
and similar, use suitable pulling devices.
Disassembly and assembly works must be performed at a clean working place. Use the special tools
developed for that purpose. Prior to installing again the parts, clean the contact surfaces of housing and
covers from old sealing residues. Possibly formed burrs or similar irregularities must be removed with an oil
stone. Housing and cover must be cleaned with a suitable detergent, in particular in the corners. Parts which
are damaged or heavily worn down must be renewed. Here, an expert must assess, whether parts such as
antifriction bearings, stop discs etc., which are subjected to normal wear during operation, can be reused.
Parts such as sealing rings, retaining plates, split pins etc. must generally be renewed. Radial sealing rings
with worn down or torn sealing lip must also be renewed. Particularly make sure that no chips or other
foreign bodies remain in the housing. Lubricating oil bores and grooves must be checked for unhindered
passage.
Prior to their installation, all bearings must be treated with service oil.
REFE- For heating up parts such as bearings, housings etc, only a heating furnace or an electric
RENCE: drier is permitted to be used!
Parts which are mounted in warm condition must be subsequently driven in after having
cooled down to ensure a tight contact.
CAUTION
When assembling the gearbox, absolutely observe the indicated torque limits and adjustment data. Screws
and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of possible functional failures, for gearboxes, the use of liquid sealants as well as of Molykote in the
control unit is not permitted.
Discs with organic friction linings (e.g. paper discs) must not be washed (affecting the adhesion of the
lining).
They must be cleaned with a dry method (leather cloth).
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
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Off-Road Driveline
Systems Division
Structure of the Service Manual
The structure of this manual follows the sequence of the working steps for the complete disassembly of the
unit in dismantled condition.
Special tools required for the performance of the respective repair works are listed within the text as well as
in chapters "W" (List of special tools) and "WB" (Illustrated tool tables).
Important Information Concerning the Work Safety
Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarise themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The persons in charge of the repair are obliged to perform the training.
The following safety references are used in the present Workshop Manual:
You will always find this symbol in the present repair instructions
CAUTION where references regarding special working procedures, methods,
information, the use of working aids etc. are given.
This symbol indicates situations where lacking care can entail

DANGER damage to persons or the product.
____________________________________________
REFE- Prior to starting the checks and repair works, carefully read the present instructions..
RENCE:
REFE- Illustrations, drawings and parts do not always represent the original; it is the working
RENCE: procedure which is shown.
The illustrations, drawings and parts are not represented true to scale; conclusions regarding
size and weight must not be drawn (not even within one representation).
The works must be performed according to the description..
REFE- After the repair works and the checks, the expert staff members must convince themselves
RENCE: that the product is properly functioning again..
5871 133 002 0/3

Off-Road Driveline
Systems Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Density lineaire en kg/m; Density superficielle en t/m2
Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Uniteo Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
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Off-Road Driveline
Systems Division
VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25.40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2.205 lb ( pounds )
9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per square inch lbf/in2 )
0.070 bar ( 0.071 kp/cm2 ) =

1 psi ( lbf/in2 )
1 Liter =
0.264 Gallon ( Imp. )
4.456 Liter =
1 Gallon ( Imp. )
=
1 Liter 0.220 Gallon ( US )
3.785 Liter =
1 Gallon ( US )
1609.344 m =
1 Mile ( Landmeile )
0° C ( Celsius ) =
+ 32° F ( Fahrenheit )
0 ° C ( Celsius ) = 273.15 Kelvin
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Off-Road Driveline
Systems Division
TORQUE LIMITS FOR SCREWS (in Nm) AS PER ZF-STANDARD 148
Friction coefficient: µ total= 0.12 for screws and nuts without aftertreatment, as well as for phosphated
nuts. Tightening by hand!
Unless otherwise specified, tightening torques may be taken from the following list:
Metric ISO-standard thread DIN 13, sheet 13
Dimension 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-fine thread DIN 13, sheet 13

Dimension 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
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Systems Division
LETTERING OF THE TYPE PLATE

ZF - REVERSING GEARBOX 4 WG-92 TSC
1 4WG-98 TSC
TA 65370 2
3 4660 063 003
1 = Gearbox type (e.g. 4WG-98 TSC)
2 = Serial number (e.g. TA 65370)
3 = ZF-parts list number (e.g. 4660 063 003)
INFORMATION FOR SPARE PARTS ORDERING:
When ordering genuine ZF spare parts, the following information shall be included:
}
1. Gearbox type
2. Serial number These data can be taken from the type plate!
3. ZF parts list number
4. Make and type of the vehicle
5. Designation of the spare part
6. Spare part number
7. Kind of dispatch
If all information indicated above are given, wrong deliveries

in connection with spare part orders will be avoided.
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5871 133 002
LAYOUT 4 WG-98 TSC

1 = Converter
2 = Transmissionpump 1 2
3 = Power take-off
4 = Input 3 3
5 = Clutch shaft "KF" 12
6 = Clutch shaft "KR"
4
Workshop Manual
7 = Clutch shaft "K2"
8 = Clutdh shaft / Output "K3"
9 = Clutch shaft "K1" 5 4
10 = Transfer Box TB92-I4
11 = Output gear 6 10
12 = Clutch shaft
13 = KR-Spur gear 7 5
0/8
8 6
2
7
3 11
Technology and Axle

Off-Road Driveline
4
Systems Division
10 9
12
1 13
5871 133 002
LAYOUT TB 98-I4
9 8
1= Intermediate shaft 1
2= Mounting face 4 WG-98 TSC
3= Input shaft
Workshop Manual
4= Breather transfer box TB92-I 4
5= Output Flange (Front axle )
6= Output shaft
6
7= Output flange (Rear axle )
8= Transfer box TB 92-I4
9= Powershift transmission 4 WG-98 TSC 7
0/9
5
7 1 2
Technology and Axle

Off-Road Driveline
Systems Division
5 4 3
5871 133 002
INSTALLATION VIEW 4 WG-98 TSC & TB92-I4
FRONT VIEW 1 2 3 4 5
1 = Transfer box TB 92-I4
Workshop Manual
2 = Model idendification plate - transfer box
3 = Diaphragm - direct mounting
4 = Converter
5 = Powershift transmission 4-WG-98 TSC
6 = ZF-Fein filter
7 = Oil filler tube with oil dipstick
8 = Model indentification poate - powershift transmission 6
9 = Breather - transfer box
0/10
10 = Oil filler plug 7/8" - 14 UN-2A

11 = Oil drain plug 7/8" - 14 UN-2A
12 = Output flange - rear axle
12
7
Technology and Axle

Off-Road Driveline
Systems Division
11
10 9 8
5871 133 002
INSTALLATION VIEW 4 WG-98 TSC & TB92-I4
REAR VIEW 1 2 3 4 5 6
1 = Cover plate
Workshop Manual
2 = ZF-Fein filter
3 = Power take-off; coaxial, engine-dependent
4 = Breather - Powershift transmission
5 = Lifting lug
6 = Powershift transmission 4-WG-98 TSC
7 = Transfer box TB 92-I4 7
8 = Output flange - rear axle
0/11
9 = Output flange - front axle

10 = Transmission suspension holes M16x1,5
11 = Oil drain plug 7/8" - 14 UNF
12 = Valve block electro-hydraulic control
(Directional clutch and pressure control)
Technology and Axle

Off-Road Driveline
Systems Division
12
10 10 11 10 9
Off-Road Driveline
Systems Division
MEASURING POINTS and CONNECTIONS

The measurements have to be carried out at hot transmission (about 80° - 95° C) !
Necessary measuring datas - see ZF-operation instruction manual (ZF Order-no.: 5872 135 002)!
CONNECTIONS TORQULIMITS
15 = Connection to heat exchanger 7/8“ - 14 UNF 35 Nm
16 = Connection from heat exchanger 7/8“ - 14 UNF 35 Nm
MEASURING POINTS for Pressure Oil and Temperature TORQULIMITS

51 = In front of converter – opening pressure 8+2 bar M10x1 6 Nm
53 = Clutch - Forward 16+3 bar KV M10x1 6 Nm
55 = Clutch - Reserve 16+3 bar KV M10x1 6 Nm
56 = Clutch 16+3 bar K1 M10x1 6 Nm
62 = Lubrication pressure K3 0,2 - 1,2 bar M10x1 6 Nm
63 = Behind the converter Temperature 100° C; short-time 120° C 3/4“ - 16 UNF 28 Nm
65 = System pressure 16+3 bar M10x1 6 Nm
67 = Modulation pressure see page-1 M10x1 6 Nm
Measuring points modulation pressure: Measuring points at reversal:
P1 = 65 1-1 = 56
P2 = 53 bzw. 55 2-2 = 57
PPM = 53 bzw. 55 3-3 = 58
PN = 65 4-3 = 58
PS = 65 3-4 = 58
60
53
Y3
Y1
63
15
Y2
3 56
16
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Off-Road Driveline
Systems Division
Periphery: Solenoid:
1 = Transmission pump Y1 = Clutch forward

2 = Valve block electro-hydraulic control Y2 = Clutch reverse
(Directional clutch and pressure control) Y3 = Clutch KV/K4
3 = Breather - transfer box TB92-I4 Y4 = Clutch K3/K2
4 = Breather – Powershift transmission 4 WG-98 TSC Y5 = Clutch K1
Y6 = Neutral
51
65
1
4
Y3
Y6
63
Y1 Y4
2 Y5
55
Y2
67 57 62 58
Coding
• SOLENOID VALVES UNDER ENGAGED
VOLTAGE CLUTCH
DRIVING DIRECT. SPEED Y1 Y2 Y3 Y4 Y5 Y6
FORWARD 1 • • • • K1 KV
2 • • • • KV K2
3 • • • K3 KV
4 • • K4 K3
REVERSE 1 • • • KR K1
2 • • • KR K2
3 • • KR K3
NEUTRAL
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Off-Road Driveline
Systems Division
SPECIFICATION CONCERNING THE REQUIRED

OIL QUALITY AND OIL FILLING VOLUME:
Oil quality/oil type: Only oils are permitted to be used which have the qualification according
to the ZF list of lubricants TE-ML 03 !
The ZF lists of lubricants are updated every two years and

can be obtained or studied as follows:
-in all ZF works
-in all ZF After-Sales Service Centres
-Internet http://www.zf.com - Deutsch/English - Information – Technical Information – List of Lubricants ...
In the respective ZF lists of lubricants, you will find information on the following:
Oil specification - Manufacturer - Product designation
such as ................ ...........................
Transmission oils without and
with Limited-Slip additives etc..
Grease for lubricating points...
Oil filling volumes
Reversing gearbox (4 WG –98 TSC): approx. 11 litres (sump volume) for the gearbox to be newly
filled (i.e. after completion of disassembly and assembly).
External oil volumes (e.g. converter, cooler, lines, etc.)
depend on the vehicle.
Transfer box (TB-92 I4): approx. 1.6 litres
Data regarding oil level checks, oil and filter changes may be taken from the ZF operating manual.
ZF Operating Manual ⇒ Ordering No. 5872 135 002
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Off-Road Driveline
Systems Division
LIST OF TOOLS FOR DISASSEMBLY AND ASSEMBLY
ZF – WG-98 TSC + TB
4660 063 003
Disassembly Assembly Designation and Application Part No.

Chapter/Fig. Chapter/Fig.
1/ 2 2/91 Assembly carriage compl. with turning device # 5870 350 000
1/46 Support # 5870 350 115
For clamping and turning the compl. gearbox or housing
Part I on the assembly carriage.
1/ 5 Two-armed extractor # 5870 970 004

Universal use.
For withdrawing the output flanges 4474 375 012.
1/7 Lifting strap 5870 281 026

1/8 Universal use.
For various lifting works.
1/10 Pulling screws 1 set = 2 units 5870 204 005

Universal use.
For repairing the disc brake system
1/12 Grip # 5873 012 011

1/40 For withdrawing the bearing inner ring 4660 273 001;
1/68 0735 371 700 and 4950 203 001; 0735 295 from the input,
1/82 output and intermediate shaft and K3.
To be used in combination with:
Basic tool, size II 5873 002 001
1/18 2/138 Adjusting screws M6 5870 204 049

To facilitate disassembly and assembly of the lateral cover
4660 306 125 at the valve housing 4660 306 124.
1/23 Adjusting screws M8 5870 204 058

Universal use.
To facilitate disassembly and assembly of plate 4660 306
130 and seal 4660 306 131 at the gearbox housing.
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Off-Road Driveline
Systems Division
4660 063 003

1/28 Strap wrench 5870 105 005

Universal use.
For screwing off the filter cartridge 0750 131 056.
1/30 Assembly lever 1 set = 2 units 5870 345 036

1/37 For inserting the two needle bearings 0501 321 047 into
1/42 the lower bearing bore of the knuckle.
1/41 Grip # 5873 001 036

1/65 For withdrawing bearing inner ring 4660 251 007; 0735
1/73 371 670 from shaft 4660 355 008 or clutch K1.
For withdrawing bearing inner ring 4660 251 012; 0735
371 745 from clutch KV and KR.
Forcing insert # 5870 026 100
Basic tool, size I 5873 001 000
1/47 2/88 Lifting chain 3-strand 42.000N 5870 281 047

Universal use.
For various lifting works. For separating and combining
the two housing halves.
1/49 General-purpose spoon 2 units required 5870 345 071

Universal use.
For separating of housing- and gearbox parts.
1/51;1/58 2/15; 2/21 External pliers set A1-A2-A3-A4 5870 900 015
1/61;1/69 2/45; 2/61 Universal use.
1/86; 1/89 2/83; For removing and mounting externally clamping circlips
DIN 471.
1/56 Three-armed extractor SPW 130 / SPT 105 5870 971 002
Universal use.
For withdrawing various gearbox parts, shafts, bearings,
flanges etc.. – K1, K4.
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Off-Road Driveline
Systems Division
4660 063 003

1/61 2/15 Pressing bush # 5870 506 128

1/89 2/55 For preloading the plate springs 0750 106 076 in clutch
K4; K3.Permits mounting and removing of the retaining
rings 0630 501 031.
1/65 Rapid grip # 5873 011 011

1/77 For withdrawing bearing inner ring 4660 274 001 ; 0735
371 699 from clutch K4 ; K2 ;KV and KR.
Forcing insert # 5870 026 100
1/68 Grip # 5873 000 029

For withdrawing bearing inner ring 4660 251 008 ; 0735
371 662 from clutch KV and KR.
Basic tool, size 0 # 5873 000 000
1/70 Three-armed extractor SPW 230 / SPT 150 5870 971 003
Universal use.
For withdrawing various gearbox parts, shafts, bearings,
flanges etc. – clutch KV and KR.
1/83 Grip # 5873 001 048

For withdrawing bearing inner ring 1319 203 021; 0735
371 690 from clutch K3.
Basic tool, size I # 5873 001 000
1/99 Internal extractor Ø 45 – 58 mm 5870 300 007

Universal use.
For withdrawing the bearing bush 0501 316495 from the
stator shaft.
Counter support 5870 300 003
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Off-Road Driveline
Systems Division
4660 063 003

2/8 Support 5870 058 092

For driving in bearing outer rings NP944 668 = 4660 274
001 into the gearbox housing.
Can only be used in combination with:
Grip 5870 260 002
2/19;2/39 Digital depth gauge 5870 200 072

2/59;2/113 Universal use.
For various measurements, e.g. clearance of the discs.
2/44 Feeler gauge 5870 200 113

Universal use.
For determining the thickness of the retaining ring.
2/94 Adjusting screws 1 set = 2 units 5870 204 007

2/104 Universal use.
For positioning and aligning the housing- and sealing
parts.
2/107 Support # 5870 048 219

For inserting shaft sealing ring 0768 800 025 , 0734 310
386 = 55 x 75 x 8 into the connection gear housing.
2/113 Measuring ledge # 5870 200 022

Universal use.
For performing various measurements.
2/132 Adjusting screw # M8/8.5 5870 204 057

2/147 2 units required!
For positioning and aligning the housing- and sealing parts
at the shift block.
2/154 Support # EBM = 4 mm 5870 048 200

For inserting shaft sealing ring 60 x 90 x8 = 0734 309 363
into the gearbox housing.
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Off-Road Driveline
Systems Division
4660 063 003

2/159 Support # 5870 058 021

2/164 For inserting bearing outer rings 0735 295 137 into the
gearbox housing Transfer - Box.
Grip 5870 260 002
2/168 Support # EBM = 1.0 mm 5870 048 276

For inserting shaft sealing ring 0634 319 121 into the
Transfer-housing - input.
2/171 Support # EBM = 3.5 mm 5870 048 277

For inserting shaft sealing ring 0634 319 121 into the
Transfer-housing – output.
2/175 Support 5870 057 030

For pressing retaining plate 4660 303 032 onto the input
screw connection..
Grip 5870 260 002
# = particularly important tools
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Repair Manual And Axle Systems
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Off-Road Driveline
Systems Division
1. DISASSEMBLY
Only for gearbox version „with“ bracket:
(Fig. No. 1)
Unfix screw connection and remove bracket.
Fig. 1
Fasten gearbox to assembly carriage

– see also Fig. No. 14, page 1/5.
(S) Assembly carriage 5870 350 000

(S) Holding fixture 5870 350 115
Fig. 2
1.1 TB 92-I4 (Transfer Box):

Unfix locking screw and drain oil from Transfer-Box.
– use suitable collector.
If required, also drain oil from the reversing gear – see Fig. No.
14, page 1/5.
Fig. 3
Remove retaining plate, unfix hexagon screws and remove

together with washer.
Fig. 4
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Off-Road Driveline
Systems Division
Withdraw flange.
(S) Two-armed puller 5870 900 004
Fig. 5
Remove shaft sealing ring.
Analogously dismantle second output flange.
Fig. 6
Secure Transfer Box with strap and unfix screw connection

(Transfer Box/reversing gear).
(S) Lifting strap 5870 281 026
Fig. 7
Isolate Transfer Box from reversing gear.
Difficult dismantling due to cylindrical pin fixing – see arrow!
Fig. 8
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Off-Road Driveline
Systems Division
Unfix housing screw connection.
Fig. 9
Separate housing halves using forcing screws.
(S) Forcing screws (M 10) 5870 204 005
Fig. 10
Legend to Fig. No. 11:
1 = Input shaft
1 2 2 3 2 = Intermediate shaft
3 = Output shaft
Withdraw shafts (with bearing inner rings) from housing and

remove bearing outer rings.
For roller bearings which will not be exchanged, pay

attention to the following:
Record (mark) the installation position (shaft) as well as the
individual bearing assignment (bearing outer ring to bearing
Fig. 11 inner ring !
Withdraw bearing inner rings from the shafts.

inner ring !
(S) Grip 5873 012 011

(S) Basic tool 5873 002 001
Fig. 12
5871 133 002 1/3

Off-Road Driveline
Systems Division
If required – unfix hexagon screw and remove sleeve with

breather.
Assembly of the Transfer Box – see section 2.2, page 2/43 !
Fig. 13
5871 133 002 1/4

Off-Road Driveline
Systems Division
1.2 REVERSING GEAR:
Unfix locking screw and drain oil from the reversing gear.
– use suitable collector.
Fig. 14
1.2.1 Gear Shift Control:

Unfix screw connection of the valve housing.
Fig. 15
Withdraw compl. gear shift control with intermediate plate.
Pay attention to pressure spring (arrow 1) becoming free and ball

(arrow 2) !
1
2
Fig. 16

5
1 = Gear shift control compl.
2 = Intermediate plate
3 3 = Ball
4 = Pressure spring
5 = Solenoid valve
1 4
5 2
Fig. 17
5871 133 002 1/5

Off-Road Driveline
Systems Division
1.2.1.1 Shifting Component:

General information:
If functional failures should occur at the gearbox – due to a defective shifting system, we recommend to replace the complete
shifting component on exchange basis.
ZF ordering-No. – for compl. shifting component – see information in the respective spare parts list.
Suitable workshop equipment in our after-sales service points (testbench for shifting systems or gearboxes) as well as
permanently trained staff ensure a skilled repair.
The following description of disassembly and assembly (Disassembly Fig. No. 17 ... 22, page 1/6 ... 1/7, Assembly –
section 2.1.14.1 page 2/37) is only meant for informing after-sales service points of ZF and the vehicle manufacturer, who
are availing on the respective workshop equipment and particularly trained expert staff.
Replace 2 screws of the cover screw connection by adjusting

screws (see arrows), unfix residual screws.
Then, uniformly unfix nuts of the adjusting screws

Cover is under spring preload.
Withdraw cover and seal.
(S) Adjusting screws (M6) 5870 204 049

(with nuts)
Fig. 18
Legend to No. 19:
1 = Valve housing
2 = Spool
3 = Pressure spring
3 4 = Sleeve
1 5 = Pressure spring
5 2
7 6 = Piston
4 7 = Adjusting disc (inserted in piston)
6 Withdraw components of the modulation valve from the valve

housing.
Fig. 19
4b Legend to Fig. No. 20:
1 = Valve housing
2 = Reversing piston
4a
1 3 = Spacer
4a = Solenoid valve „Y1“
4b = Solenoid valve „Y2“
2 Withdraw components from the valve housing and disassemble

both solenoid valves.

3
Mark installation position of the two solenoid valves – assembly
Fig. 20 aid !
5871 133 002 1/6

Off-Road Driveline
Systems Division
Dismantle both recoil valves – see also Fig. No. 21 – and remove
all locking screws.
Fig. 21
Recoil valve
1 = Locking screw (with O-Ring)
2 = Pressure spring
3 3 = Ball
Fig. 22
Replace 2 screws of the plate screw connection by adjusting

screws (see arrows), unfix residual screws.
Withdraw cover and seal arranged behind.
Fig. 23
Converter back pressure valve:
Remove piston and pressure spring from the bore.
Fig. 24
5871 133 002 1/7

Off-Road Driveline
Systems Division
d a = Solenoid valve „Y3“

a b = Solenoid valve „Y4“
b c = Solenoid valve „Y5“
d = Solenoid valve „Y6“
c
Unfix cylindrical screw, remove retaining plates and withdraw
solenoid valves.
Fig. 25 1.2.2 Oil Pressure Pump:
The oil pressure pump can only be replaced as complete

unit! The system pressure valve is preset by the
manufacturer and is not permitted to be changed without
approval by ZF!
System pressure valve:
Unfix locking screw.
Fig. 26
Withdraw piston and pressure spring from the bore.
Pay attention to adjusting spacer(s) becoming free – inserted

into piston !
Fig. 27
Unscrew oil filter.
(S) Strap wrench 5870 105 005
Fig. 28
5871 133 002 1/8

Off-Road Driveline
Systems Division
Unfix screw connection and withdraw compl. pressure oil pump.
Fig. 29
Remove both cylindrical screws (arrows).
Separating pump case carefully and uniformly,

damage danger of the inside bearing bushes!
(S) Assembly lever 5870 345 036
Fig. 30
Mark installation position of the pump wheels (assembly aid).
Visual inspection of bushes and pump wheels as well as of the

pump housing (wear traces).
In case of serious wear – affecting the required pump pressure or

the oil delivery volume – the pressure oil pump must be
completely replaced!
Individual components cannot be replaced!
Fig. 31
Remove O-Rings (arrows).
Fig. 32
5871 133 002 1/9

Off-Road Driveline
Systems Division
Dismantle oil filling pipe (with O-ring and oil dipstick).
Fig. 33
1.2.3 Converter:
Horizontally turn gearbox.
Withdraw complete converter.
Fig. 34
Remove shaft sealing ring.
Fig. 35
1.2.4 Power Take-off:

Unfix screw connection of the converter bell.
Fig. 36
5871 133 002 1/10

Off-Road Driveline
Systems Division
Separate converter bell from the power take-off housing and

remove gasket.
Difficult disassembly due to cylindrical pin fixing!
Fig. 37
If required – remove both bearing outer rings and both

cylindrical pins (arrows).

inner ring !
Fig. 38
Withdraw shaft (converter output) from power take-off housing.

Unfix rectangular ring (arrow) and remove it.
Fig. 39
Withdraw both bearing inner rings from the shaft (converter

output).

inner ring !
(S) Grip „Super“ 5873 012 011

(S) Basic tool 5873 002 001
Fig. 40
5871 133 002 1/11
Off-Road Driveline
Systems Division
Remove shaft (pressure oil pump drive) from power take-off

housing and withdraw both bearing inner rings.

inner ring !
(S) Grip „Super“ 5873 001 036

(Lg. Timken NP 65 28 65)
(S) Forcing insert 5870 026 100
Fig. 41
If necessary – remove both bearing inner rings from the bores of

the power take-off housing.

inner ring !
Unfix screw connection and force off power take-off housing.
Fig. 42
Dismantle breather (arrow).
Fig. 43
1.2.5 Converter Safety Valve:

Force off converter safety valve and remove both O-rings
(arrow).
Fig. 44
5871 133 002 1/12
Off-Road Driveline
Systems Division
Force off shaft sealing ring.
Fig. 45
Turn gearbox by 180°.
Newly locate gearbox – position locating device (arrow)

at the Transfer-Box flange surface (gearbox housing
„Part I“).
Unfix housing screw connection.
(S) Assembly carriage 5870 350 000

(compl. with turning device)
(S) Locating device 5870 350 115
Fig. 46
Carefully lift gearbox housing „Part II“ off the

gearbox housing „Part I“,
the individual clutches remain in the gearbox housing
„Part I“
(S) Lifting chain 5870 281 047

Annular screws 3 x M14, DIN 580
Fig. 47
1.2.6 Turbine Shaft:

Unfix both cylindrical screws and remove them together with
straps (turbine shaft fixing).
Fig. 48
5871 133 002 1/13

Off-Road Driveline
Systems Division
Force off turbine shaft.
(S) General-purpose spoon (2x) 5870 345 071
Fig. 49
Unhook and remove rectangular ring.
Fig. 50
Remove retaining ring and withdraw ball bearing.
(S) External pliers set 5870 900 015
Fig. 51
Remove all bearing outer rings from gearbox housing

„Part II“.

inner ring !
Remove all oil pipe.
Fig. 52
5871 133 002 1/14

Off-Road Driveline
Systems Division
Remove O-Ring (arrow).
Fig. 53
1.2.7 Clutch „K4“:
Lift the complete clutch pack „K4“ out of the gearbox housing
(Part I) – to that end, somewhat lift clutch „C.R.“ (arrow).
Fig. 54
Unhook and remove rectangular rings.
Fig. 55
Pull off bearing inner ring with inner plate carrier.

inner ring !
(S) Three-armed puller 5870 971 002
Fig. 56
5871 133 002 1/15

Off-Road Driveline
Systems Division
Remove roller cage half (along with guard plate) from the inner
plate carrier and outer plate carrier.
Fig. 57
Squeeze out retaining ring.
Fig. 58
Squeeze out snap ring.
Fig. 59
Take shim and disc pack out of the disc carrier.
Fig. 60
5871 133 002 1/16

Off-Road Driveline
Systems Division
Equalise preload of the plate spring pack by means of press and

pressing sleeve.
Now, squeeze out retaining ring.
(S) Pressing sleeve 5870 506 128

Fig. 61
Remove shim and plate spring pack.
Fig. 62
Press piston by means of compressed air off the shaft, resp. out
of the disc carrier.
Fig. 63

Check function of the vent valve (ball) (crimped in the piston –
however freely movable in the bore) (Arrow) !
Fig. 64
5871 133 002 1/17

Off-Road Driveline
Systems Division
Pull off bearing inner ring.


inner ring !
Do not carry out further disassembly – the shaft (with helical
gear and disc carrier) is only exchangeable as complete unit !
(S) Grip „Super“

Clutch (K4 / K2) 5873 011 011
Clutch (K1) 5873 001 036
(S) Basic tool 5873 001 000
Forcing insert 5870 026 100
Fig. 65
1.2.8 Clutch „C.F.“:
Lift the complete clutch „C.F.“ out of the gearbox housing (Part
I) – to that end, somewhat lift clutch „C.R.“ (arrow).
Fig. 66
Hook out both rectangular rings (arrows) and remove them.
Fig. 67
5871 133 002 1/18

Off-Road Driveline
Systems Division
Pull off bearing inner ring.

attention to the following :
inner ring) !
(S) Grip „Super“ 5873 000 029

(S) Basic tool 5873 000 000
Fig. 68
Fig. 69
Pull off disc carrier (inner discs) with roller bearing.
If necessary, remove both bearing outer rings from the disc

carrier.

For roller bearings, which are not exchanged, observe the
following:
Record (mark) installation position (shaft) as well as the
individual bearing assignments (bearing outer- to bearing
inner ring).
(S) Three-armed puller 5870 971 003
Fig. 70
5871 133 002 1/19

Off-Road Driveline
Systems Division
Fig. 71
Withdraw end shim and disc pack from the disc carrier.
Fig. 72
Withdraw bearing inner ring.

inner ring) !
(S) Grip „Super“ 5873 001 036

(S) Basic tool 5873 001 000
Fig. 73
5871 133 002 1/20

Off-Road Driveline
Systems Division
Fig. 74
Fig. 75
Check function of the vent valve (ball) (crimped in the piston,

however freely movable in the bore) (arrow).
Fig. 76


inner ring !
Do not carry out further disassembly – shaft (with helical gear
and disc carrier) is exchangeable only as complete unit !
(S) Grip „Super“ 5873 011 011

(S) Basic tool 5873 001 000
Fig. 77
5871 133 002 1/21
Off-Road Driveline
Systems Division
1.2.9 Clutch „C.R.“:

Lift complete clutch pack „C.R.“ out of gearbox housing (Part I).
Carry out further disassembly of the clutch “C.R.“ in the

same way as shown in the illustration 1.2.8 Clutch „C.F.“, -
see Fig. No. 67, page 1/18 ....... Fig. No. 77, page 1/21!
Fig. 78
1.2.10 Clutch „K3“:

Unfix screw connection (difficult disassembly due to use of
Loctite) and withdraw screen „Part I“.
Fig. 79
Lift complete clutch pack „K3“ off the gearbox housing (Part I).
Fig. 80
Unhook and remove both rectangular rings.
Fig. 81
5871 133 002 1/22

Off-Road Driveline
Systems Division

inner ring !
(S) Grip „Super“ 5873 012 011

(S) Basic tool 5873 002 001
Fig. 82

inner ring !
(S) Grip „Super“ 5873 001 048

(Lg. Koyo UK ST4276 C)
(S) Basic tool 5873 001 000
Fig. 83
Withdraw disc carrier (inner discs).

Remove loose components (guard plate and roller ring) from
disc carrier.
Fig. 84
5871 133 002 1/23

Off-Road Driveline
Systems Division
Withdraw second roller ring and guard plate from the shaft..
Fig. 85
Fig. 86
Fig. 87
Take end shim and disc pack out of the plate carrier.
Fig. 88
5871 133 002 1/24
Off-Road Driveline
Systems Division
Equalise preload of the plate spring pack by means of press and

pressing sleeve.
Now, squeeze out retaining ring.
(S) Pressing sleeve 5870 506 128

Fig. 89
Fig. 90
Do not carry out further disassembly – the shaft (with helical

gear and disc carrier) is only exchangeable as complete unit !
Fig. 91
Check function of the vent valve (ball) (crimped in the piston –

however freely movable in the bore) (arrow) !
Fig. 92
5871 133 002 1/25

Off-Road Driveline
Systems Division
1.2.11 Clutch „K1“:

Lift the complete clutch pack „K1“ out of the gearbox housing.
(Part I).
Carry out further disassembly of the clutch “K1“ in the same

way as shown in the illustration 1.2.7 Clutch „K4“, -see Fig.
No. 55, page 1/15 ....... Fig. No. 65, page 1/18 !
Fig. 93
Unfix screw connection (difficult disassembly due to use of

Loctite) and remove screen „Part II“.
Fig. 94
1.2.12 Clutch „K2“:

Lift the complete clutch pack „K2“ out of the gearbox housing.
(Part I).
Carry out further disassembly of the clutch “K2“ in the same

way as shown in the illustration 1.2.7 Clutch „K4“, -see Fig.
No. 55, page 1/15 ....... Fig. No. 65, page 1/18 !
Fig. 95
Remove all bearing outer rings from gearbox housing

„Part I“.

inner ring !
Fig. 96
5871 133 002 1/26

Off-Road Driveline
Systems Division
Disassemble suction tube and oil tube (difficult

disassembly/screws due to use of Loctite).
Fig. 97
Loosen screw connection of stator shaft (difficult

disassembly/screws due to use of Loctite) and withdraw stator
shaft.
Fig. 98
If necessary, withdraw bearing bush.
(S) Internal extractor 5870 300 007

(S) Counter support 5870 300 003
Fig. 99
5871 133 002 1/27

Off-Road Driveline
Systems Division
2. ASSEMBLY
2.1 REVERSING GEARBOX:
2.1.1 GEARBOX HOUSING „PART I“:
2.1.1.1 Stator Shaft:

Press bearing bush into stator shaft, until it is in tight contact.
Fig. 1
Insert pre-assembled stator shaft and fasten stator shaft with

cylindrical screws.
Use securing compound (Loctite No. 586) when screwing in the

cylindrical screws!
Tightening torque (M10/8.8) ................ MA = 46 Nm
Fig. 2
2.1.1.2 Oil Tube / Suction Tube:

Oil both O-rings (arrows) and line them up at the oil tube.
Fig. 3
Mount pre-assembled oil tube.

cylindrical screws!
Fig. 4
5871 133 002 2/1

Off-Road Driveline
Systems Division
Oil O-ring (arrow) and line it up at the suction tube.
Fig. 5
Mount pre-assembled suction tube.

cylindrical screws!
Fig. 6
Insert screen „Part II“ and fasten with cylindrical screws.

cylindrical screws!
Fig. 7
Insert all bearing outer rings.
Legend to Fig.:
1 = K1
2 = K2 *
3 1 3 = K3
4 = K4 *
5 5 = C.R. *
2 6 = C.F. *
6
4
Pay attention to installation position and bearing assignment
– also see disassembly instruction page 1/26, Fig. No. 96!
(S) * Support 5870 058 092

Fig. 8 Grip 5870 260 002
5871 133 002 2/2

Off-Road Driveline
Systems Division
2.1.2 Pre-assembling Clutches “K1”, “K2” and “K4”:

Legend to Sketch Nr. 9 ... Fig. Nr. 28:
16
1 = Shaft compl. (with spur gear, disc
10 13 carrier and retaining ring)
11 2 = Piston
3 = Plate spring pack
12 4 = Support shim
10 11 5 = Retaining ring
6 = Disc pack
8 9 7 = End shim
5 8 = Snap ring (S = optional)
3 10 = Guard plate
6 11 = Roller cage
2 12 = Disc carrier (inner)
13 = Roller bearing
14 = Roller bearing
15 = Rectangular ring
Represented in the sketch is clutch „K4“.

14 1
The assembly of clutches „K1“, „K2“ and „K4“ must
15 be performed analogously.
Fig. 9 However, the differing number of discs and with it

the modified disc clearance – see information on page
2/5 – must be considered!
Check pressure oil supply and lubrication oil supply bores for
unhindered passage (with compressed air).
Fig. 10
Check the function of the vent valve (arrow) (assembly bore

crimped, however ball is freely movable in the piston) !
Fig. 11
5871 133 002 2/3

Off-Road Driveline
Systems Division
Oil sealing lip of the piston and sealing surface of shaft and disc
carrier.
Insert piston (2), until contact is obtained (pay attention to the

installation position – see illustration) !
Fig. 12

Line up spring pack (3) – stacking and installation position of the
single plate springs – see sketch-No. 9.
Position the upper plate spring centrally – with grease (assembly

aid).
Fig. 13
Line up support shim (4).
Fig. 14
Preload plate spring pack (3) – by means of sleeve – until the

retaining ring (5) can be squeezed in.
(S) Pressure piece 5870 506 128
(S) Pliers set 5870 900 015
Fig. 15
5871 133 002 2/4

Off-Road Driveline
Systems Division

Alternately insert disc pack (6) alternately – starting with one
outer disc.
Fig. 16
Mount end shim (7) and squeeze in snap ring (8) (S=optional).
Fig. 17
2.1.2.1 Setting/Checking Disc Clearance:

8 F F X x = Disc clearance
7 F = approx. 40 N
1 = Shaft (with disc carrier – see sketch-No. 9)
6 6 = Disc pack
7 = End shim
8 = Snap ring (S = optional)
K1 Disc clearance per friction surface = 0.10 ... 0.15 mm

e.g. 12 lined discs = 24 friction surfaces
1 gives total disc clearance 2.4 ... 3.6 mm
Fig. 18
K2 Disc clearance per friction surface = 0.10 .... 0.15 mm

gives total disc clearance 1.6 ...... 2,4 mm
K4 Disc clearance per friction surface = 0.10 .... 0.15 mm

gives total disc clearance 1.6 ...... 2,4 mm
5871 133 002 2/5

Off-Road Driveline
Systems Division
Press disc pack against shoulder (F = approx. 40 N).
Determine dimension "I" from the end face of the disc carrier to
the end shim.
Dimension "I" e.g.. ........................................ 8.65 mm
(S) Digital depth gauge 5870 200 072

Fig. 19
Position end shim (7) and snap ring (8) on the outer face of the
recess/disc carrier, until contact is obtained – see Illustration.
Determine dimension "II" from the end face of the disc carrier to
the end shim.
Dimension "II" e.g.. ...................................... 7.30 mm
Fig. 20 CALCULATION EXAMPLE:

Dimension „I“ e.g. ......................................... 8,65 mm
Dimension „II“ e.g. . ..................................... - 7,30 mm
gives dimension X (disc clearance) = 1.35 mm
If the required total disc clearance e.g..

K1 2.4 ... 3.6 mm
K2 1.6 ... 2,4 mm
K4 1.6 ... 2,4 mm
should not be reached, correct with a suitable snap ring (10)
(S = optional)!
Squeeze in retaining ring (9).
Fig. 21
5871 133 002 2/6

Off-Road Driveline
Systems Division
Line up a guard plate (10).
Fig. 22
Make one roller cage (11) adhere with grease in the inner disc
carrier (assembly aid).
Pay attention to the installation position of the roller cage –

large/small roller cage diameter – see sketch-No. 9!
Fig. 23
Align discs radially and centrally (assembly aid).
Introduce disc carrier (12), until all inner discs are lined up.
Fig. 24
Insert outer roller cage (11) and line up second guard plate (10).
At a correct assembly (all discs lined up, correct installation

position of the two roller cages), the guard plate must not
protrude beyond the locating face of the bearing inner ring (13) –
to be checked !
Fig. 25
5871 133 002 2/7

Off-Road Driveline
Systems Division
Press bearing inner ring (13) against shoulder.

– also see disassembly instruction page-1/15, Fig. No. 56!
Fig. 26

Fig. 27
Squeeze in rectangular rings (15 and 16) and hook them.
For installation of complete clutch "K1" – see page 2/21.

Fig. 28
5871 133 002 2/8

Off-Road Driveline
Systems Division
2.1.3 Pre-assembling Clutches "C.F." and "C.R.":

Legend to Sketch Nr. 29 ... Fig. Nr. 48:
15 12 1 = Shaft compl. (with spur gear, disc
11 carrier, snap ring and ball)
2 = Piston
9 10 3 = Plate spring pack
4 = Support shim
8 5 = Roller bearing
5 6 = Disc pack
7 4 7 = End shim
6 9 = Disc carrier (inner discs)
3 10 = Roller bearing
2 11 = Retaining ring
12 = Roller bearing
13 = Roller bearing
Represented in the sketch is clutch „C.R.“.

1
The assembly of clutches „C.F.“ and „C.R.“
13 14 must be performed analogously.
Fig. 29
Fig. 30
Check the function of the vent valve (arrow) (assembly hole

crimped – however ball is freely movable in the piston).
Fig. 31
5871 133 002 2/9

Off-Road Driveline
Systems Division
Oil sealing lips of the piston and sealing surface of shaft and disc
carrier.
Insert pre-assembled piston (2), until it is in contact (pay

attention to the installation position – see illustration)!
Fig. 32

Line up plate spring pack (5) – stacking and installation position
of the single plate springs – see sketch-No. 29.
Position upper plate spring centrally – with grease – (assembly

aid)!
Fig. 33
Fig. 34
Check (central) position of the upper plate spring – see reference

in Fig. No. 34!

Fig. 35
5871 133 002 2/10

Off-Road Driveline
Systems Division

Alternately place disc pack (6) – starting with an outer disc.
Fig. 36
Place end shim (7) and squeeze in snap ring (8) (S=optional).
Fig. 37
8 2.1.3.1 Setting/Checking Disc Clearance:

X
7 X = Disc clearance
1 = Shaft (with disc carrier – see sketch-No. 29)
6 6 = Disc pack
7 = End shim
8 = Retaining ring (S = optional)
C.R. e.g. 11 lined discs = 22 friction surfaces

Total disc clearance 2.2 .... 3.3 mm
1
C.F. e.g. 11 lined discs = 22 friction surfaces
Fig. 38 Total disc clearance 2.2 .... 3.3 mm
Press disc pack against shoulder (F = approx. 40 N).
Determine dimension I from the end face of the disc carrier to

the end shim.
Dimension I e.g. ........................................ 8.35 mm
Fig. 39
5871 133 002 2/11

Off-Road Driveline
Systems Division
recess/disc carrier, until it is in contact – see Figure.
Determine dimension II from the end face of the disc carrier to

the end shim.
Dimension II e.g. ...................................... 5.55 mm
Fig. 40
CALCULATION EXAMPLE:
Dimension I e.g. ....................................... 8,35 mm

Dimension II e.g. ............................ - 5,55 mm
gives dimension X (disc clearance) = 2,80 mm
If the required total disc clearance e.g. (2.2 ... 3.3 mm) should
not be obtained, correct it with a suitable snap ring (8)
(S = optional)
If disassembled –
insert both bearing outer rings of the roller bearings (5 and 10)
into the disc carrier, until contact is obtained.
Fig. 41


– also see disassembly instruction 1/19, Fig. No. 70!
Fig. 42
5871 133 002 2/12

Off-Road Driveline
Systems Division

Press on the bearing inner ring (10), until the rollers of the roller
bearings (5 and 10) have a playfree contact, however no pre-load
is achieved.

At this step, the disc carrier has to be rotated several times in
both directions to ensure the settling of the single rollers.

Fig. 43
Determine the thickness of the retaining ring for the disc

carrier bearing fixing:
Determine thickness of the required retaining ring (11) by means

of feeler gauge (from end face/bearing inner ring to outer contact
face/groove).
The base for an exact determination of the required retaining

ring is the correct roller bearing positioning !
(S) Feeler gauge 5870 200 113

Fig. 44

Select thickness of the retaining ring (S=optional) so that a
playfree fixing of the disc carrier bearing will be achieved.
Squeeze in the determined retaining ring (11).
Reset the retaining ring, until contact on the groove base is

obtained!
Fig. 45

Fig. 46
5871 133 002 2/13

Off-Road Driveline
Systems Division

Fig. 47
Squeeze in both rectangular rings (14 and 15) and hook them.
For installation of complete clutch "C.F." – see page 2/22.

For installation of complete clutch "C.R." – see page 2/22.
Fig. 48
5871 133 002 2/14

Off-Road Driveline
Systems Division
2.1.4 Pre-assembling Clutch „K3“:
1 Legend to Sketch Nr.49 .... Fig. Nr. 69:
1 = Shaft compl. (with spur gear, disc

carrier, snap ring and ball)
15 2 = Piston
3 = Plate spring pack
12 14 4 = Support shim
13 5 = Retaining ring
11 6 = Disc pack
8 10 7 = End shim
9 8 = Snap ring (S = optional)
10 = Guard plate
6 4 11 = Roller cage
12 = Disc carrier (inner plates)
2 3 13 = Roller cage
14 = Guard plate
15 = Roller bearing
16 = Roller bearing
16 18 = Rectangular ring
18 17
Fig. 49
Fig. 50
Check the function of the vent valve (arrow) (assembly hole

crimped – however ball is freely movable in the piston).
Fig. 51
5871 133 002 2/15

Off-Road Driveline
Systems Division
Oil sealing lips of the piston and sealing surface of shaft and disc
carrier.
Insert pre-assembled piston (2), until it is in contact (pay

attention to the installation position – see illustration)!
Fig. 52

Line up plate spring pack (3) – stacking and installation position
of the single plate springs – see sketch-No. 49.
Position upper plate spring centrally – with grease – (assembly

aid)!
Fig. 53
Fig. 54
Preload plate spring pack (3) – by means of sleeve – until the

retaining ring (5) can be squeezed in.
(S) Pressure piece 5870 506 128
Fig. 55
5871 133 002 2/16

Off-Road Driveline
Systems Division

Alternately insert disc pack (6) – starting with one outer disc.
Fig. 56
Mount end shim (7) and squeeze in snap ring (8) (S=optional).
Fig. 57
8 F F
2.1.4.1 Setting/Checking Disc Clearance:
X
7 x = Disc clearance
F = abt. 40 N
6 1 = Shaft (with disc carrier – see sketch-No. 49)
7 = Disc pack
8 = End shim
K3 Disc clearance per friction surface = 0.10 ... 0.15 mm

1 gives total disc clearance 1.6 ... 2.4 mm
Fig. 58
Press disc pack against shoulder (F = abt. 40 N).
Determine dimension I from the end face of the disc carrier to

the end shim.
Dimension I e.g..... .................................... 8.30 mm
Fig. 59
5871 133 002 2/17

Off-Road Driveline
Systems Division
recess/disc carrier, until it is in contact – see Figure.
Determine dimension II from the end face of the disc carrier to

the end shim.
Dimension II e.g. ...................................... 6.90 mm
Fig. 60
CALCULATION EXAMPLE:
Dimension I e.g. ....................................... 8,30 mm

Dimension II e.g. ................................... - 6,90 mm
gives dimension X (disc clearance) = 1.40 mm

If the required total disc clearance e.g. (1.6 ... 2.4 mm) should
not be obtained, correct it with one corresponding snap ring (8)
(S = optional)
Fig. 61
Line up a guard plate (10).
Fig. 62
5871 133 002 2/18

Off-Road Driveline
Systems Division
Line up roller cage (11).

great/small roller cage diameter – see Fig. No. 63 and also
Sketch No. 49!
Fig. 63

Fig. 64
Insert outer roller cage (13).

great/small roller cage diameter – see Fig. No. 65 and also
Sketch No. 49!
Fig. 65
Line up guard plate (14).
At a correct assembly (all discs lined up, correct installation

position of the two roller cages), the guard plate must not
protrude beyond the contact face of the bearing inner ring (15) –
to be checked !
Fig. 66
5871 133 002 2/19

Off-Road Driveline
Systems Division

Fig. 67

Fig. 68
Squeeze in both rectangular rings (17 and 18) and hook them.
For the installation of the complete clutch "K3" – see

page 2/21.
Fig. 69
5871 133 002 2/20

Off-Road Driveline
Systems Division
2.1.5 INSERTING THE PRE-

ASSEMBLED CLUTCHES:
Insert pre-assembled clutch „K2“.
Pay attention to the rectangular rings – risk of cracking!

Position the rectangular rings centrally – with grease –
(assembly aid).
Fig. 70

Position the rectangular rings centrally – with grease – (assembly
aid).
Fig. 71

aid).
Fig. 72
Fasten screen „Part I“ with cylindrical screws.

cylindrical screws!
Tightening torque (M6/8.8) ..................... MA = 9.5 Nm
Fig. 73
5871 133 002 2/21

Off-Road Driveline
Systems Division
Insert pre-assembled clutch „C.R.“.

aid).
Fig. 74
Insert pre-assembled clutch „C.F.“.

aid).
Fig. 75

aid).
Fig. 76
5871 133 002 2/22

Off-Road Driveline
Systems Division
2.1.6 Pre-assembling HOUSING

„Part II“:
Check permeability of the diaphragm (threaded pin) – with
compressed air – or, when mounting a new part, insert it into the
K3 lube oil supply bore of the gearbox housing „Part II“.
Legend to Sketch:
1 = gearbox housing
2 = Diaphragm
3 = Locking screws
1 3 2 3
Fig. 77
Tightening torque (M8) ................... MA = 18 Nm
Pre-assemble oil tubes:
Grease both O-ring (arrows) and line them up at the oil tube.
Fig. 78
Insert all pre-assembled oil tubes.

cylindrical screws!
Tightening torque (M8/8.8) ............. MA = 23 Nm
Fig. 79
Insert all bearing outer rings into the gearbox housing "Part II"
(make adhere with grease – assembly aid).
1 Legend to Fig.:
3 1 = K1
2 = K2
6 3 = K3
5 2
4 = K4
5 = C.R.
6 = C.F.
4
Fig. 80 – also see disassembly instruction page 1/14, Fig. No. 52 !
5871 133 002 2/23

Off-Road Driveline
Systems Division
6 2.1.7 TURBINE SHAFT:
Legend to Sketch No. 81 .... Fig. No. 85:
1 = Input shaft
2
3
4
=
=
=
Turbine shaft
Snap ring
Ball bearing
} Turbine shaft compl.
(completion part)
2 3 1 4 5 5 = Retaining ring
Fig. 81
Press ball bearing (4) onto input shaft (1), until it is in contact.
Fig. 82
(S) Pliers set 5870 900 015
Fig. 83
Squeeze in and hook rectangular ring (6).
Fig. 84
5871 133 002 2/24

Off-Road Driveline
Systems Division
Insert pre-assembled turbine shaft and fasten it with straps and

cylindrical screws.
Fig. 85
2.1.8 COMBINING THE GEARBOX

HOUSING HALVES:
Insert O-ring (2) into the annular groove (arrow).
Fig. 86
Apply sealing compound (Loctite No. 586) to the contact surface

of the gearbox housing halves "Part I / Part II".
Fig. 87
Check central position of the rectangular rings at the various

shafts – assembly aid (Carefully combine gearbox housing
halves – risk of cracking of the rectangular rings!) !
Combine the gearbox housing halves carefully!

Bring turbine shaft (spur gear) into assembly position by rotating
movements!
(S) Lifting chain, 3-strand type 5870 281 047
Fig. 88
5871 133 002 2/25

Off-Road Driveline
Systems Division
Insert both cylindrical pins (gearbox housing half fixing).
Fig. 89
Bolt gearbox housing halves together using hexagon screws,

suitably placing the retaining yoke (installation position – see
arrow).
Observe different screw lengths !
Fig. 90
Turn gearbox by 180° .
Newly locate gearbox – position locating device

at the bracket flange surface (gearbox housing „Part II“) –
see illustration (arrows).
(S) Clamping plate 5870 350 115
Fig. 91
2.1.9 CONVERTER SAFETY VALVE:

Insert converter safety valve (compl. part), until it is in contact.
1 Legend to Sketch:
2 1 = Valve body
2 = Disc
3
3 = Ball
Fig. 92
5871 133 002 2/26

Off-Road Driveline
Systems Division
2.1.10 POWER TAKE-OFF:

Apply sealing compound(Loctite No. 586) to contact surface of
gearbox housing / power take-off housing.
Insert both O-rings into the annular grooves (arrows)
Fig. 93
Turn 2 units adjusting screws (M 10) into the gearbox housing

and line up power take-off housing..
(S) Adjusting screws (M 10) 5870 204 007
Fig. 94
Do not tighten hexagon screws – only screw them in.

Remove adjusting screws.
Observe different screw lengths!
Insert both cylindrical pins (position – see arrows).
Fig. 95
Finally tighten hexagon screws.
Fig. 96
5871 133 002 2/27

Off-Road Driveline
Systems Division
Insert both bearing outer rings (arrows), until they are in contact.
Pay attention to installation position and bearing

assignment! Also see disassembly instruction on page-1/12,
Fig. No. 42!
Fig. 97
Press both bearing inner rings onto the shaft (converter output),
until they are in contact.

Fig. No. 40!
Fig. 98
Squeeze in and hook rectangular ring (arrow).
Fig. 99
Insert pre-assembled shaft.
Fig. 100
5871 133 002 2/28

Off-Road Driveline
Systems Division
Press both bearing inner rings onto the shaft (output gear), until
they are in contact.

Fig. No. 41!
Fig. 101
Insert pre-assembled shaft.
Fig. 102
Glue both bearing outer rings (arrows) with grease into the
housing (converter bell) – assembly aid.

Fig. No. 38!
Fig. 103
Turn 2 units adjusting screws (M 10) into the power take-off

housing and line up the gasket.
(S) Adjusting screws (M 10) 5870 204 007
Fig. 104
5871 133 002 2/29

Off-Road Driveline
Systems Division
Line up pre-assembled housing (converter bell) and fix with both

cylindrical pins.
Fig. 105
Remove adjusting screws and fasten housing with hexagon

screws.
Fig. 106
Mount shaft sealing ring (2 – see sketch No. 108).
Installation position of shaft sealing ring – sealing lip facing the

oil compartment (see sketch-No. 108).
Outer shell of the shaft sealing ring
- if of metal apply sealing compound (Loctite No. 586)
- if rubberised wet with spirit
Grease shaft sealing ring near the sealing- and dust lip.
(Grease „Renolit EP 2“ ZF ordering No. 0671 190 079).
A plain installation position of the shaft sealing ring must be
ensured – use suitable support !
Fig. 107
(S) Support 5870 048 219
Legend to Fig.:
2
1 1 = Housing (converter bell)
2 = Shaft sealing ring
Fig. 108
5871 133 002 2/30

Off-Road Driveline
Systems Division
2.1.11 CONVERTER:
Position 1 unit disc, each, (s = 1.00 mm) on the diaphragm
flange webs (4x).
Fig. 109
Position diaphragm (2 units).
Observe installation position!

Spot-welded reinforcing discs of the diaphragm always towards
the outside – see arrows!
Fig. 110
Fasten diaphragm with hexagon screws (fitted with washer)!
Observe washers arranged underneath the diaphragm - - see

Fig. No. 109!
Insert hexagon screws with securing compound
(Loctite No. 262) !
Fig. 111
Introduce complete converter, until splines of turbine shaft and

stator shaft are engaged.
Fig. 112
5871 133 002 2/31

Off-Road Driveline
Systems Division
Control measure for lined up converter – from top diaphragm to

flange surface/housing (converter bell) – see Fig. No. 113
L = approx. 56 mm.
The indicated control measure only serves for the installation of

the converter, not for the assembly of engine/gearbox!
(S) Measuring ledge 5870 200 022
Fig. 113
Secure converter with quick-acting straps (assembly- and

transport guard) !
Fig. 114
Mount breather (arrow) with sealing compound (Loctite No.

243).
Tightening torque (M10x1) MA = 6 Nm
Fig. 115 2.1.12 HYDR. PRESSURE PUMP:

The hydraulic pressure pump can only be replaced as one
5 4 unit ! The system pressure valve integrated in the pump is
1 2 preset by the manufacturer and must by no means be
6 3 changed without the approval of ZF.
Oil pump components and install them in the pump housing (1).
5
Legend to Fig. No. 116 ... Fig. No. 121:
1 = Pump housing 4 = Pump wheel II
2 = O-Ring 5 = Cylindrical pin
3 = Pump wheel I 6 = System pressure valve
Fig. 116 Observe installation position of the pump wheels – insert pump
wheels with chamfered tooth side showing downwards – also see
disassembly instructions - page 1/9, Fig. No. 31!
5871 133 002 2/32

Off-Road Driveline
Systems Division
Line up pump cover and position it by means of socket

screws uniformly against shoulder !
Tightening torque (M10/12.9) .................. MA = 115 Nm
Fig. 117
Fix O-rings (see arrows) in the annular grooves (using grease –

assembly aid) or line them up at the collar.
Fig. 118
Place pre-assembled hydraulic pressure pump and fasten it with

cylindrical and hexagon screws (observe screw length).
Tightening torque (M12/10.9) ................. MA = 115 Nm

Tightening torque (M10/8.8).................... MA = 46 Nm
Fig. 119
System pressure valve:

1 The setting of the system pressure valve must not be changed
without the approval of ZF !
2
3 Legend to Fig. No. 120 ... No. 121:
2 = Adjusting spacers
3 = Piston
4 = O-ring
4 5 = Locking screw
Fig. 120
5871 133 002 2/33

Off-Road Driveline
Systems Division
Insert components of the system pressure valve into the bore of

the hydraulic pressure pump, see Fig. No. 120.
Tightening torque (M ..)................... MA = .. Nm
Fig. 121
2.1.13 OIL FILTER/OIL FILLER TUBE:

Mount filter.
Carry out filter assembly – according to instructions/see filter

shell (ZF original filter)!
Fig. 122
1 = Oil filler tube

1
2 = O-ring
3 3 = Oil dipstick
Line up O-ring at the oil filler tube.

Insert oil dipstick into oil filler tube.
2
Fig. 123
Fasten pre-assembled oil filler tube with cylindrical screws.
Tightening torque (M8/8.8)................... MA = 23 Nm
Fig. 124
5871 133 002 2/34

Off-Road Driveline
Systems Division
2.1.14 GEARSHIFT SYSTEM:

1
2
3 Legend to Fig. No. 125 ... No. 127:
4
5 1 = 4 / 2 way valve
2 = O-ring (20x2 CH-75)
3 = O-ring (18x2 CH-75)
4 = O-ring (16x2 CH-75)
5 = O-ring (15x2 CH-75)
Check and oil O-rings (4x) of the solenoid valve.

Fig. 125
a = Solenoid valve „Y4“

a b = Solenoid valve „Y5“
Insert solenoid valves, fasten with holder and cylindrical screw.

b
Observe installation position – see picture !
Tightening torque (M6/8.8)................... MA = 9.5 Nm
Fig. 126
c = Solenoid valve „Y4“
Insert solenoid valve, fasten with holder and cylindrical screw.
Observe installation position – see Fig. !

c
Tightening torque (M6/8.8)................... MA = 9,5 Nm
Fig. 127
Legend to Fig. No. 128 ... No. 129:

1 1 = 3 / 2 way valve
2 = O-ring (20x2 CH-75)
2 3 = O-ring (18x2 CH-75)
3 4 = O-ring (17x2 CH-75)
4
Fig. 128
5871 133 002 2/35

Off-Road Driveline
Systems Division
d = Solenoid valve „Y6“
Insert solenoid valve, fasten with holder and cylindrical screw.

d
Observe installation position – see Fig. !
Fig. 129
Converter backpressure valve:
Legend to Fig. No. 130 ... No. 131:

2
1 = Pressure spring
1 2 = Piston
Check piston for damage or wear !
Fig. 130
Insert pressure spring and piston of the converter backpressure

valve.
Fig. 131
Screw in two adjusting screws (M 8) – see arrows – and line up

gasket.
(S) 2 units adjusting screws (M 8, 8.5 mm) 5870 204 057
Fig. 132
5871 133 002 2/36

Off-Road Driveline
Systems Division
Line up plate and fasten with hexagon screws – removing

adjusting screws
Fig. 133 2.1.14.1 Shifting Component:

Legend to Sketch No. 134 ... Fig. No. 144:
7 1 = Valve housing
6 2 = Spoon (modulation valve)
13 5 3 = Pressure spring
9 4 = Sleeve (spring guide)
5 = Pressure spring
8 6 = Adjusting spacer (s) (s = optional)
7 = Piston (displacement type)
11 8 = Gasket
9 = Cover
10 = Piston compl. (reversing valve)
11 = Spacer
4 12 = Recoil valves
10 (ball/pressure spring and locking screw)
3 13 = Solenoid valve „Y1“ (C.F.)
14 = Solenoid valve „Y2“ (C.R.)
12
1 Prior to the assembly, check components for
damage or wear !
Prior to installation, check free movement of the

movable pars in the housing !
2 Oil components before installing them !
14
Fig. 134
Insert diaphragm C-2 (stud M5).

Check diaphragm for free passage !
Tightening torque (M5)................... MA = 2,5 Nm
Fig. 135
5871 133 002 2/37

Off-Road Driveline
Systems Division
Modulation valve:
1
Taking the illustration as a basis, insert control piston (2),
pressure spring (3), sleeve (4), pressure spring (5), adjusting
3 spacer(s) (6) and piston into the bore of the valve housing (1).
5 2
7 4
6
Fig. 136
Reversing valve:
Taking the illustration as a basis, insert piston compl. (10) and

spacer (11) into the bore of the valve housing (1).
11 10
Fig. 137
Screw in two adjusting screws (arrows) and line up gasket (8).
8
(with nuts)
Fig. 138
Line up cover and bring it into uniform contact using nuts.
Fig. 139
5871 133 002 2/38

Off-Road Driveline
Systems Division
Fasten cover with hexagon screws and washers – removing the

adjusting screws.
Fig. 140

1 1 = 3 / 2 way valve
2 = O-ring (20x2 CH-75)
2 3 = O-ring (18x2 CH-75)
3 4 = O-ring (17x2 CH-75)
4
Fig. 141
Introduce both solenoid valves (13 + 14), fasten with holder and
cylindrical screw.

Observe installation position (plug opening showing upwards)
– see Fig. No. 142 or Sketch No. 134 !
14 Tightening torque (M6/8.8)................... MA = 9.5 Nm
13
Fig. 142
Recoil valves:
Insert ball and pressure spring into both bores – see picture.
Fig. 143
5871 133 002 2/39

Off-Road Driveline
Systems Division
Screw in both locking screws – fitted with O-ring.
Tightening torque (M24x1.5)................... MA = 30 Nm
Fig. 144
Recoil valve:
Glue ball (arrow) with grease into the bore.
Fig. 145
Introduce pressure spring into the bore.
Fig. 146
Screw in two adjusting screws and line up lined intermediate

plate – paying attention to the pressure spring (arrow) !
The lined intermediate plate is permitted to be mounted (used)

only once !
(S) 2 units adjusting screws (M 8, 8.5 mm) 5870 204 057
Fig. 147
5871 133 002 2/40

Off-Road Driveline
Systems Division
Line up pre-assembled shifting component, fasten with hexagon

screws and washers – removing the adjusting screws.
Fig. 148
2.1.15 LOCKING SCREWS and OIL DRAIN PLUG:
Fig. 149 Fig. 150 Fig. 151
Screw in all locking screws (M10x1) – fitted with O-ring.

Position – see arrows (Fig. No. 149/150/151).
Tightening torque (M10x1)................... MA = 6 Nm
Screw in oil drain plug – fitted with O-ring
Tightening torque (7/8“ – 14 UN 2A) .............. MA = 30 Nm
Fig. 152
5871 133 002 2/41

Off-Road Driveline
Systems Division
2 2.1.16 SHAFT SEALING RING (output):

3 Legend to Sketch No. 153 and Fig. No. 154:
1 X
1 = Gearbox housing
2 = Output shaft „K3“
X = Installation measure 4.0 + 0.5 mm
Fig. 153 Mount shaft sealing ring (3) considering the required installation
position (measure „X“ - see Sketch No. 153).
Installation position of shaft sealing ring – sealing lip showing

towards the oil compartment (see Sketch No. 153).
Contact surface (outer shell of the shaft sealing ring, if:

– metal apply sealing compound (Loctite No. 586).
– rubberised wet with spirit.
Grease shaft sealing ring near the sealing and dust lip.
Fig. 154
(S) Support 5870 048 200
5871 133 002 2/42

Off-Road Driveline
Systems Division
2.2 TB 92-I4 (Transfer-Box):

7 Legend to Sketch No. 153:
X
6 4 8 1 = Gearbox housing
5 2 = Breather
3 = Input shaft
4 = Intermediate shaft
5 = Output shaft
7 = Output flange
1 8 = Shaft sealing ring
6 2 3 X = Flange surface
7
Fig. 155
Legend to Sketch No. 156 and Fig. No. 157:
3 1 = Gearbox housing
2 2 = Sleeve
3 = Hexagon nut (counter nut)
4 = Breather
4
Fig. 156
Screw in sleeve (2), counter with counter nut (3) and then mount
breather (4).
Mount parts with sealing compound (Loctite No. 243) .
Tightening torque (M 16)...................... MA = 195Nm

Tightening torque (M10x1)................... MA = 6 Nm
Fig. 157
Insert both cylindrical pins (arrows).
Fig. 158
5871 133 002 2/43

Off-Road Driveline
Systems Division
Insert all bearing outer rings into the bores of housing

„Part I“, until it is in contact.
Observe installation position and assignment of bearings

– see disassembly reference page 1/3, Fig. No. 11 !
(S) Support 5870 058 021

Grip 5870 260 002
Fig. 159
Mount heated up bearing inner rings onto input shaft, mount

intermediate shafts and output shaft – reset after the bearing
inner rings have cooled down!
Observe installation position and assignment of bearings –

see disassembly reference page 1/3, Fig. No. 12 !
Fig. 160
Only when installing new parts:
Mount locking cover (2) with sealing compound (Loctite

1
No. 518) into the input shaft (1) – see picture.
Fig. 161
Legend to Fig.:
3 1 = Input shaft
1 2 2 2 = Intermediate shaft
3 = Output shaft
Insert all shafts into gearbox housing „Part I“- see picture.
Observe installation position and assignment of bearings– see

disassembly reference page 1/3, Fig. No. 12 !
Fig. 162
5871 133 002 2/44

Off-Road Driveline
Systems Division
Apply sealing compound (Loctite No. 586) to the contact

surfaces of gearbox housing „Part I / Part II“.
(S) Support 5870 058 021

Grip 5870 260 002
Fig. 163
Glue all bearing outer rings into the bores of housing „Part II“
with grease – assembly aid.

Observe installation position and assignment of bearings –
see disassembly reference page 1/3, Fig. No. 11 !
Fig. 164
Place pre-assembled gearbox housing „Part II“ and fasten with

hexagon screws.
Fig. 165
Insert cylindrical pin into the reversing gearbox housing.
Fig. 166
5871 133 002 2/45

Off-Road Driveline
Systems Division
3 2 1 2.2.1 SHAFT SEALING RING (input):

X
Legend to Sketch No. 167 and Fig. No. 168:
1 = Gearbox housing
3 = Input shaft

Fig. 167 Mount shaft sealing ring (2) considering the required installation
position (measure „X“ – see Sketch No. 167).

towards the oil compartment (see Sketch No. 167).
Contact surface (outer shell of shaft sealing ring), if:

Fig. 168 (S) Support 5870 048 276
Carefully line up Transfer Box at the reversing gearbox,

uniformly bring it into contact using hexagon screws and fasten.
Fig. 169
7 2.2.2 FLANGE/SHAFT SEALING

4
8 RING (output):
5 6 Legend to Sketch No. 170 ... Fig. No. 175:
1 2 X
1 = Gearbox housing
3 = Output shaft
3 4 = Flange
5 = Screen
6 = Disc
7 = Hexagon screws
Fig. 170
8 = Retaining plate
5871 133 002 2/46

Off-Road Driveline
Systems Division

Mount shaft sealing ring (2) considering the required installation
position (measure „X“ – see Sketch No. 170).

towards oil compartment (see Sketch No. 170).
Contact surface (external shell of shaft sealing ring), if:

Fig. 171 A plain installation position of the shaft sealing ring must be
(S) Support 5870 048 277
Press screen (5) onto flange (4), until it is in contact –

considering the installation position, see Sketch No. 170.
Use suitable pressure piece, screen must by no means be

deformed. !
Fig. 172
Line up heated up flange.
Fig. 173
Place disc (6) and fasten flange with hexagon screws.
Fig. 174
5871 133 002 2/47

Off-Road Driveline
Systems Division
Fix hexagon screws with retaining plate (8).
(S) Support 5870 057 030

Grip 5870 260 002
Mount the second shaft sealing ring/flange analogously

- see Fig.No. 170 ... Fig. No. 175 !
Fig. 175
2.2.3 OIL DRAIN PLUG AND OIL

FILLING-/CONTROL SCREW:
Screw in oil drain plug and oil filling-/control screw – fitted with
O-ring.
Tightening torque (7/8" – 14 UN 2A).............. MA = 30 Nm
Fig. 176
2.3 BRACKET:
Only for version „with“ bracket:
Fasten bracket with hexagon screws – fitted with washer.
Fig. 177
Prior to starting operation of the unit, observe the

information or directions and references in the ZF operating
instructions as well as instructions and references of the
vehicle manufacturer !
5871 133 002 2/48

5871 133 002 - ZF - REVERSING GEARBOX 4 WG-98 TSC + TB92-I4 (Telescopic Handler Side Mount Compact + Transfer Box) Workshop Manual

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5871 133 002 - ZF - REVERSING GEARBOX 4 WG-98 TSC + TB92-I4 (Telescopic Handler Side Mount Compact + Transfer Box) Workshop Manual

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Ordering No.

: 5871 133 002

Abt.: ASTDM / Division: ASTDM

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

5871 133 002 0/1

5871 133 002 0/2

Structure of the Service Manual

Important Information Concerning the Work Safety

This symbol indicates situations where lacking care can entail

5871 133 002 0/3

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

Note : linear density in kg/m; areal density in t/m2

Nota : Density lineaire en kg/m; Density superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

5871 133 002 0/4

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

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

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

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

0.070 bar ( 0.071 kp/cm2 ) =

0 ° C ( Celsius ) = 273.15 Kelvin

5871 133 002 0/5

TORQUE LIMITS FOR SCREWS (in Nm) AS PER ZF-STANDARD 148

Metric ISO-fine thread DIN 13, sheet 13

5871 133 002 0/6

LETTERING OF THE TYPE PLATE

3 4660 063 003

1 = Gearbox type (e.g. 4WG-98 TSC)

2 = Serial number (e.g. TA 65370)

3 = ZF-parts list number (e.g. 4660 063 003)

INFORMATION FOR SPARE PARTS ORDERING:

3. ZF parts list number

4. Make and type of the vehicle

5. Designation of the spare part

6. Spare part number

If all information indicated above are given, wrong deliveries

5871 133 002 0/7

LAYOUT 4 WG-98 TSC

Technology and Axle

Technology and Axle

INSTALLATION VIEW 4 WG-98 TSC & TB92-I4

10 = Oil filler plug 7/8" - 14 UN-2A

Technology and Axle

INSTALLATION VIEW 4 WG-98 TSC & TB92-I4

9 = Output flange - front axle

Technology and Axle

MEASURING POINTS and CONNECTIONS

MEASURING POINTS for Pressure Oil and Temperature TORQULIMITS

Measuring points modulation pressure: Measuring points at reversal:

5871 133 002 0/12

1 = Transmission pump Y1 = Clutch forward

5871 133 002 0/13

SPECIFICATION CONCERNING THE REQUIRED

The ZF lists of lubricants are updated every two years and

Oil filling volumes

5871 133 002 0/15

LIST OF TOOLS FOR DISASSEMBLY AND ASSEMBLY

Disassembly Assembly Designation and Application Part No.

1/ 5 Two-armed extractor # 5870 970 004

1/7 Lifting strap 5870 281 026