For ZF12-speed gearbox peripheral parts disassembly
Eleven tasks need to be completed for the disassembly of ZF12-speed gearbox peripheral parts:
1. Disassemble the speed sensor harness;
2. Disassemble the gearbox control device;
3. Remove the breather bolt;
4. Disassemble the gear selection module;
5. Disassemble the sensor module;
6. Disassemble the valve body;
7. Disassemble the contact;
8. Disassemble the output shaft speed sensor;
9. Disassemble the odometer sensor and disassemble the retarder;
10. Disassemble the power take-off and install the cover.
Tools used: torque wrench, sensor module guide pin [S399171ZF107], hexagonal wrench, T30 wrench, T45 wrench,
T40 wrench, 19 socket, 17 socket wrench and extension rod, Lama tool, hammer, positioning pin removal tool.
Operation steps:
1) Loosen the speed sensor buckle under the transmission;
2) Pull out the speed sensor connector;
3) Gently loosen the speed sensor connector buckle at the rear auxiliary box and remove the speed sensor connector;
4) Loosen the speed sensor clamp and remove the speed sensor harness;
5) Use a torque wrench and socket to loosen the 27 M8 hexagonal bolts on the transmission control device; Note: Do not use an air gun to completely damage the transmission control device.
6) Remove the two diagonal bolts;
7) Install two locating pins;
8) Remove the remaining 25 fixed bolts in turn;
9) Remove the transmission control device smoothly;
10) Loosen and remove the locating pin. Note: Electronic components are integrated in the transmission control device. Do not bump or disassemble without locating pins.
11) Remove the gasket;
12) Use a hexagonal wrench to remove the breather cap. Note: The breather bolt can be installed again to prevent loss. The breather bolt can only be removed after the transmission controller is removed.
13) Use a t30 wrench to loosen and remove the 9 plum bolts on the gear selection module;
14) Remove the gear selection module and the gasket together; Note: The gasket is a disposable part and needs to be replaced during maintenance.
15) Remove the gear selection fork positioning pin. Note: The sealing ring is connected to the shift control mechanism through a loss protection device.
16) Use a t30 wrench to loosen the 10 plum bolts on the sensor module in sequence;
17) Lift the sensor module;
18) Release the stuck plum bolts and remove the sensor module.
19) Use a t45 wrench to loosen the 7 external plum bolts on the valve body; Note: The plum bolts on the valve body are designed to prevent loss, so do not remove them.
20) Loosen the three plum bolts inside the valve body;
21) Remove the valve body;
22) Remove the air intake connector and filter element on the valve body side. Note: The filter element can be replaced. When removing it, push the filter element out from the connector side.
23) Remove the 2 bolts on the contact sensor connector;
24) Pull out the sensor plug;
25) Remove the contact/cable from the cable clamp;
26) Use a t40 wrench to remove the 4 m8 plum bolts on the contact;
27) Remove the contact; Note: When removing, remove the bolts fixing the upper part of the contact last. The contact and the stroke sensor are an assembly, and it is forbidden to remove the sensor fixing bolts.
28) Remove the front protective cover;
29) Remove the sealing ring;
30) Remove the sealing ring of the contact.
31) Rotate the transmission 90°;
32) Remove a fastening bolt;
33) Remove the output shaft speed sensor.
34) Use a torque wrench to remove the odometer speed sensor.
35) Use 19-socket and extension rod to remove 2 hexagonal bolts from output flange;
36) Remove gasket;
37) Install puller tool;
38) Use puller tool to pull out output flange and remove O-ring
39) Use hammer and dowel removal tool to remove dowel pin between transmission and retarder;
40) Use gantry to hook retarder;
41) Use torque wrench to remove retarder fastening bolt;
42) Remove retarder and retarder gasket;
43) Use 17-socket and wrench to loosen 2 hexagonal bolts on one side of PTO mounting cover;
44) Use 19-socket and wrench to remove 5 combination bolts on the other side of PTO and mounting cover;
45) Remove 2 hexagonal bolts on PTO mounting cover;
46) Remove PTO mounting cover;
47) Remove PTO hole cover and PTO mounting cover gasket.
