zf_16s-1650_double_h___0091_765_008_a_2005.pdf

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

1/96

M A

N U

A L

D E

E R

P

M A N U A L D E R E P A R A E S R E P A I R M A N U A

A R A E S

Caixa de C mbioGearbox

ZF 16S-1 650 0091 765 008a

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

2/96M.S.C.C. - 05/2005 - C.T.T. - Literatura Tcnica

Av. Conde Zeppelin, 1935 - CEP 18103-905Sorocaba

Caixa Postal 585 - CEP 18100-970 - So Paulo - BrasilTelefax (00 55 15) 4009-2525

A ZF se reserva o direito de fazer alteraes tcnicas neste Manual,sem prvio aviso.

With the reserve of technical modifications ZF without prior notice.

Para informaes complementares contatar nosso Depto. de Servio.Fone: (00 55 15) 4009-2627 / Fax: (00 55 15) 4009-2366

For further information is requested to contact our Service department.Phone number (00 55 15) 4009-2627 / Fax: (00 55 15) 4009-2366

Direitos autorais da ZFO presente Manual de Reparao protegido segundo os direitos do autor. Fica proibida a reproduo e dis-tribuio de qualquer tipo - tambm em forma de resumos - especialmente cpias, reproduo fotomecnicaou eletrnica, ou armazenar o contedo em equipamentos de processamento de textos ou rede de dados sema autorizao do titular do direito autoral. Qualquer infrao ser processada sob as leis civis e criminais.

Copyright by ZFThese repair instructions are protected by copyright. Any reproduction and dissemination in whatever form -also in adapted, paraphrased or extracted form - in particular as a reprint, photomechanical or eletronicreproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited an will be prosecuted under civil and criminal law.

Impresso no Brasil / Printed in Brazil

ZF do Brasil Ltda.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

3/96

VIDE I.S.NSEE S.I. N

NDICE /CONTENTS

Introduo / Introduction ......................................................................................................................... 01

Construo e Funcionamento / Construction and Function .................................................................... 03

Descrio Geral Grupo Redutor - Verso Duplo "H" / General Description Range Change Reduction - Double "H" Version .................................................. 05

Grupo Redutor - Verso "H" Sobreposto / Reduction gear groupe - Superimposed H version ......... 06

Comando Pneumtico / Pneumatic Control ............................................................................................ 08

Grupo Desmultiplicador / Splitter gear ................................................................................................... 10

Operao - Marchas Desmultiplicadas / Operation - Splited gear ......................................................... 12

Operao - Marchas Bsicas - Verso Duplo "H" / Basic Speeds Operation - Double H version ..... 13

Operao - Marchas Bsicas - Verso "H" Sobreposto / Basic Speeds Operation - Superimposed H version .... 14

Diagrama de Fluxo de Fora / Power Flow Diagram ............................................................................. 15

Sincronizao / Synchronization ............................................................................................................. 16

Inspeo dos Componentes / Parts Inspection ........................................................................................ 19

Vista Explodida e Tabela de Componentes / Exploded View and Parts List .......................................... 21

Valores de Ajustes e Torque de Aperto / Adjustment Datas and Tightening Torques............................. 36

Ferramentas Especiais / Special Tools ..................................................................................................... 37

Desmontagem / Disassembly ................................................................................................................... 45

Montagem / Assembly .............................................................................................................................. 61

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

4/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

5/96

VIDE I.S.NSEE S.I. N 01

INTRODUO

Este Manual visa atender as necessidades bsicaspara uma perfeita manuteno das Caixas de Cm-bio ZF 16S-1650.

O profissional tcnico encarregado pelo serviodever seguir rigorosamente os itens abaixo:

- Ler com ateno as instrues contidas nesteManual.

- Manter o local de trabalho limpo e organizado.

- Lavar a transmisso antes de desmont-la.

- Juntas, chapas-trava, vedadores e peas comdesgaste excessivo ou danificadas devero sersubstitudas.

- Observar se peas com desgaste normal de uso,devem ou no ser substitudas.

- Observar os valores de ajuste e torques de aper-to contidos neste Manual.

INTRODUCTION

This manual aims to give the basic needs for a perfect maintenance of gearboxes of the ZF 16S-1650.

The technician responsible by the service must strictly follow the items below:

- Read the instructions contained in this manualthoroughly and carefully;

- Keep the workplace clean and tidy;

- Wash the transmission before disassembly it;

- Gaskets; locking plates, sealing parts withdamage or excessive wear should be replaced;

- Check if parts with normal wear should bereplaced or not;

- Observe the adjustment torque specifications and pressure torques contained in this manual;

- Keep holes and lubrication channels free fromgrease or any other material;

- Carefully read the Service Information (S.I.),about possible alterations;

- Always use ZF ORIGINAL PARTS.

When ordering replacement parts for thetransmissions, mention the type, serial number of the box and the parts list.

This information is engraved on the type platesituated at the side of the housing.

- Manter os furos e canais de lubrificao semprelivres de graxa ou qualquer outro material.

- Ler com ateno as Informaes de Servio (I.S.),referentes a possveis alteraes.

- Utilizar sempre PEAS ORIGINAIS ZF.

Ao solicitar peas de reposio para as transmis-ses, deve-se mencionar o tipo, o n de srie dacaixa e a Lista Unitria.

Estes dados encontram-se gravados na Plaquetade Identificao, localizada na parte lateral dacarcaa.

IND.BRAS.Tipo

Caixa de Cmbio N

N do Cliente

Tomada deForaleo conf. Lista deLubrificantes ZF TE-MLQtde. de leo

VelocmetroRed.Total

n = xn Motor

L.Unit. N

ZF DO BRASIL S.A. IND.BRAS.Type

Gearbox N

Customer N

PTO

Oil according to list of lubrificants ZF TE-MLOil Capacity

SpeedometerTotal Radio

n = xn Engine

Parts List N

ZF DO BRASIL S.A.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

6/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

7/96


Vista da Caixa de Mudana /Gearbox view

Construo e FuncionamentoA caixa de Mudana ZF 16S-1650 composta deuma caixa bsica com 4 velocidades frente e umar, um grupo redutor (planetrio) montado poste-riormente e um grupo desmultiplicador montado

na parte dianteira da caixa.Pela combinao da caixa principal e do gruporedutor resultam 8 marchas engatadas em duplo"H" ou "H" sobreposto. Alm disso, estas marchaspodero ser desmultiplicadas atravs do grupodesmultiplicador possibilitando o uso de mais 8marchas intermedirias, somando ento 16 mar-chas totalmente sincronizadas.

03

Construction and Operation

The gearbox ZF 16S-1650 consists of a mainsection with four forward ratios and reverse, arear mounted epicyclic range-change section and an integral front-mounted splitter gear train.

The combination of the main gearbox and reduction gear group result 8 engaged speeds indouble H or else superimposed H. Inaddition, the splitter gears double the eight ratiosof the main and range change gearbox to makeavailable a total of 16 gear ratios all synchronized.

Verso duplo "H" - Double "H" Version

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

8/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

9/96


Vista em Corte /Sectional view

Descrio GeralGrupo Redutor - Verso duplo "H"O grupo redutor atua na faixa da 1 a 4 marchas er, permanecendo desacoplado na faixa de 5 a 8.

O engate e desengate do grupo redutor ocorre au-tomaticamente atravs de acionamento pneumti-co quando se passa com a alavanca de mudanada posio de 3e 4 marchas (1 H) para a posiode 5 e 6 (2 H) e vice-versa, bastando para issovencer um ponto de presso.

05

Esquema das posies da alavanca

GrupoDesmultiplicador

Splitter gear train

Caixa Bsica Main section

Grupo Redutor Range change

section

General Description

Range Change Section - Double "H" Version

The range change section acts in the range from1st to 4th speeds and reverse, and remainsuncoupled in the ranges from 5th to 8th.

The engaging and disengaging of the range changesection occurs automatically through a pneumaticdrive when is shifted from 3rd and 4th speeds (1st

H) to 5th and 6th (2nd H) and vice versa.

Double-H shift pattern

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

10/96


Grupo Redutor - Verso "H" sobrepostoEngate do GP

Com a tecla da vlvula da manopla na posio"LOW", o ar liberado para a vlvula solenide edesta para a vlvula 4/2 vias.

O fluxo de ar vindo da vlvula de acionamento doGP, passa pela vlvula 4/2 vias e esta desvia-o parao lado de engate do cilindro do GP (marchas 1/ 2/3/4 e r).

Desengate do GPAo mudar a tecla da vlvula da manopla para aposio "HIGH", o fluxo de ar interrompido.

A vlvula 4/2 vias recebe o fluxo de ar da vlvulade acionamento do GP e desta vez desvia-o para olado de desengate do cilindro do GP (marchas 5/ 6/7/8).

Vlvula SolenideEsta vlvula normalmente fica aberta, mas quandoo veculo atinge velocidades muito altas, queultrapassa os limites para a utilizao das 1 a 4marchas, a vlvula energizada e com issointerrompe o fluxo de ar proveniente da vlvulamanopla, caso esta seja inadvertidamente mudadapara a posio "LOW" e desta forma assegura queo ar proveniente da vlvula de acionamento doGP siga para o lado do desengate do cilindro doGP.

Com isso, se houver uma mudana errada de 5para 4 marcha em velocidade incompatvel, amarcha que entrar ser a 8, evitando assim danosna transmisso.

06

Reduction gear - Superimposed H version

Engaging GP

With the swtich in the position LOW, the air is released to the solenoid valve and consequently to the 4/2 wayvalve.

The air flow coming from the GP drive valve, passesthrough the 4/2 way valve and is displaced to the GPcylinder on the engaging side. ( 1st/2nd/3rd/4th and reverse).

Disengaging of the GP

When changing the switch to the position HIGH, theair flow is interrupted.

The 4/2 ways valve receives the air flow from the GPdrive valve and displaces it to GP cylinder on thedisengaging side. (5th/6th/7th/8th).

Solenoid valve

Normally this valve remains open. except when thevehicle reaches very high speeds, thus exceeding thelimits for using the 1st to 4th speeds. In this case thevalve is energized and interrupts the air flow from thehandle valve, if the same is inadvertendly changed tothe LOW position thus ensuring that the air from theGP drive valve flows to the GP cylinder on thedisengaging side.

However if it exists wrong gear changes from 5th to 4thspeeds in incompatble speed the 8th speed takes placeautomatically preventing the transmission from sufferingany damages.

Switching diagram at gearbox selector lever with rangechange valve.

Esquema das posies da alavanca

Shift pattern

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

11/96


VERSO "H" SOBREPOSTO -SUPERIMPOSED H VERSION

07

Vlvula ManoplaTecla em posio "LOW" (BAIXA)GP engatado

Handle ValveSwitch in the LOWposition.GP engaged handle valve

Vlvula deAcionamento GPGP Drive Valve

Vlvula SolenideSolenoid Valve

Vlvula 4/2 Vias4/2 Way Valve

Cilindro GPGP Cylinder

Vlvula ManoplaTecla em posio "HIGH" (ALTA)GP desengatado

Handle ValveSwitch in the HIGH positionGP disengaged.

Vlvula deAcionamento GPGP Drive Valve

Vlvula SolenideSolenoid Valve

Vlvula 4/2 Vias

4/2 Way Valve

Cilindro GPGP Cylinder

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

12/96


Comando Pneumtico / Pneumatic Control

1. Pedal da embreagem2. Reservatrio pneumtico3. Vlvula de acionamento do grupo redutor4. Vlvula pr-seletora5. Vlvula rel6. Cilindro de comando do grupodesmultiplicador7. Cilindro do comando do grupo redutor8. Vlvula de acionamento do grupo desmul-tiplicador9. Interruptor para a lmpada de aviso do gruporedutor

1. Clutch pedal2. Pneumatic reservoir 3. Reduction gear groupe drive valve4. Preselector valve5. Relais valve6. Splitter gear control cylinder 7. Range change control cylinder 8. Splitter gear drive valve9. Switch for the range change section warninglight

Verso duplo "H" / Double "H" Version

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

13/96


Comando Pneumtico / Pneumatic Control

1. Pedal da embreagem2. Reservatrio pneumtico3. Vlvula de acionamento do grupo redutor4. Vlvula pr-seletora5. Vlvula rel6. Cilindro de comando do grupodesmultiplicador7. Cilindro do comando do grupo redutor8. Vlvula de acionamento do grupo desmul-tiplicador9. Vlvula solenide

10. Vlvula 4/2 vias

1. Clutch pedal2. Pneumatic reservoir 3. Reduction gear groupe drive valve4. Preselector valve5. Relais valve6. Splitter gear control cylinder 7. Range change control cylinder 8. Splitter gear drive valve9. Solenoid valve10. 4/2 way valve

09

Verso "H" Sobreposto /Superimposed "H" Version

8

1

4

2

10

6 5

3

9

7

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

14/96


InterlockNo engate das marchas, quando houver passagensde um "H" para outro, principalmente se efetuadocom rapidez, poder acontecer que o engate dogrupo redutor no se complete, ficando a luva deengate na posio central.

O Interlock um dispositivo mecnico com a fi-nalidade de impedir que isso acontea ou seja: elebloqueia o engate das marchas da caixa de mu-dana enquanto no se completar o engate do gru-po redutor.

Interlock

It may occur that during the engaging the speeds from a H to the other mainly if the speeds arecarried out very rapid the engaging of the rangchange section is not completed remaining thesliding sleeve in the central position.

The interlock is a mechanical device that wasdesigned to avoid that kind of problem i.e. it blocksthe gearbox speeds engaging while the rangechange section is not completed.

Grupo DesmultiplicadorA relao de transmisso do grupo

desmultiplicador est determinada de forma a di-vidir praticamente ao meio os espaamentos en-tre as 8 marchas bsicas ou seja, cada marcha dacaixa de mudana possui uma posio lenta e r-pida, pr-selecionada pneumaticamente atravs datecla localizada no punho da alavanca de mudan-a e engatadas ao pisar no pedal da embreagem.

Splitter gear

The splitter gear ratio has been designed to split

the 8 speeds i.e. each speed of the gearbox has thehigh range (S) and the low range (L) which are pneumatically preselected.

The driver simply engages the splitter gear withthe control valve, and presses the clutch pedaldown.

Control valve up: high range (S)

Control valve down: low range (L)

Grupo desmultiplicador rpido

Grupo desmultiplicador lento

10

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

15/96


Relaes de trasmisso usando apenas 8 velocidades

Relaes de trasmisso usando 16 velocidades

V Km/h

V Km/h

Gear ratio using only 8 speeds

Gear ratio using 16 speeds

V Km/h

V Km/h

11

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

16/96


Operao - Marchas Desmultiplicadas

Alm das 8 marchas bsicas, a 16S - 1650 possui o

grupo desmultiplicador incorporado, possibilitandoa obteno de mais 8 marchas (desmultiplicao das8 marchas bsicas ). Essas marchas praticamente sorelaes intermedirias entre cada uma das 8 marchasbsicas, ou seja, cada marcha possui uma posiolenta (L) ou rpida (R), pr-selecionadas pneumati-camente atravs da tecla existente na alavanca demudanas e engatadas ao ser pressionado o pedal daembreagem.ExemploEstamos em 1 marcha lenta e queremos obter amarcha desmultiplicada 1 rpida.Colocamos a tecla do desmultiplicador na posi-o "R"(assim a marcha "primeira rpida" estarsendo selecionada).O engrenamento da marcha dar-se- pneumatica-mente ao se pisar no pedal da embreagem, semmudar a alavanca de posio.Se quisermos agora a 2 marcha lenta, retornamos atecla do desmultiplicador posio "L". Aoposicionarmos a alavanca de mudana na 2 marcha(para o que necessriamente teremos que pisar naembreagem), automaticamente teremos a 2 marchalenta engatada, e assim sucessivamente.

Operation - Splited gears

In addtion to the 8 basic speeds, the ZF - 16S-

1650 has the splitter gear incorporated making possible to get more 8 speeds (splitting of the 8 basic speeds). These speeds are practicallyontermidiate ratios between eahc one of the 8 basic speeds,i.e. each speed has low range (L) or high range. pneumatically preselected by the gear lever with range control valve and engaged when

pressing the clutch pedal down.

Example:

We are driving at 1st idle and want to get thesplited gear 1st rapid.

We put the control valve in the R position . (thefirst rapid speed will be selected)

The engaging of the speed is shifted pneumaticallywhen you press the clutch pedal down., without moving the the gear lever position.

If the driver wants the 2nd idle we put the controlvalve in the L position When placing the gear lever in the 2nd speed ( by pressing the clutch pe-dal down ) the 2nd speed will be engaged automatically, and so on.

12

Tecla pr-selecionando marchas lentas Preselected control valve for at idle

Tecla pr-selecionando marchas rpidas Preselected control valve for rapid speeds

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

17/96


Operao - Marchas BsicasVerso duplo "H"

As marchas bsicas so engatadas em 8 posiessequenciais, do tipo "duplo H", pela alavanca demudanas.

O primeiro "H" comprende as marchas de 1 a 4e r e uma mola posicionadora mantm a alavancana linha de engrenamento da 3 e 4.

O segundo "H" compreende as marchas da 5 a 8e para obt-las simplesmente necessrio vencerum ponto de presso aps a 4 marcha, movimen-tando-se a alavanca de mudana para a direita.

A mudana entre os "Hs" se d de forma pneum-tica atravs da movimentao lateral da prpriaalavanca de mudana.

Aps a passagem para o segundo "H", uma molaposicionadora mantm a alavanca na linha deengrenamento da 5 a 6.

13

Posio da alavanca de mudanas

Operation - basic speeds

Double "H" Version

The basic speeds can be shifted through a double-H gearshift pattern lika a normal 8-speed gearbox.

The first H comprises the speeds from 1st to4th and reverse and positioning spring keeps thelever in the gearing from 3rd to 4h speed.

The second H comprises the speeds from 5h to8th and to gewt them is simply necessary to surpassa pressure point after 4th speed, moving the gear lever to the right.

The gearshift between the Hs is performed pneumatically through the lateral movement of the proper gearshift lever.

After shifting to the second H, a positioningspring keeps the gear lever in the gearing from5th to 6th speed.

Gear lever position

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

18/96


Operao - Marchas BsicasVerso "H" sobreposto

As marchas bsicas so engatadas em 4 posiessequenciais, em forma de "H", pela alavanca demudana.

Na manopla da alavanca de mudana, existe umatecla com posies "LOW" e "HIGH".

O primeiro "H", (com a tecla na posio "LOW")compreende as marchas de 1 a 4 e r.

O "H" sobreposto, (tecla na posio "HIGH"),compreende as marchas de 5 a 8.

Assim sendo, se posicionar a alavanca de mudana

na posio 1 marcha, tecla em "LOW", teremos a1 marcha engatada.

Se continuar com a alavanca de mudana naposio 1 marcha, mas com a tecla em "HIGH",teremos agora a 5 marcha engatada.

Com a alavanca de mudana na posio 2 marcha,tecla em "LOW" teremos a 2 marcha engatada.

Com a alavanca de mudana na posio 2 marcha,mas com a tecla em "HIGH", teremos agora a 6marcha engatada.

E assim sucessivamente para as demais marchas.

Operation - Basic speeds

Superimposed H version

The basic speeds are engaged by the selector lever in 4 sequentional positions, H- shaped.

Thre handle of the selector lever shows a switchwith the positons LOW and HIGH.

The first H (with the switch in the LOW position) consists of the 1st to 4th speeds and reverse).

The double H (with the swtich in the HIGH position) consists of5th to 8th speeds.

In this case, if we place the selector lever in the1st speed position, with the switch in LOW the fist speed will be engaged.

If we maintain the selector lever in the 1st speed position, but with the switch on the HIGH position the 5th speed will be engaged.

With the selector lever placed in the 2nd speed and switch in the LOW position , the 2nd speed will be engaged.

With the selector lever placed in the 2nd speed,

but with the switch the HIGHposition the 6thspeed will engaged.

This procedure will be successively applied for the further speeds.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

19/96


Diagrama do Fluxo de Fora

O Diagrama abaixo indica o fluxo de fora emcada marcha da 16S-1650 (Verso Direct Drive).

Power Flow Diagram

The diagram below indicates the power flow ineach speed of the ZF gearbox 16S-1650 (Direct Drive Version).

GrupoDesmultiplicador

Splitter Gear

Caixa Bsica

Main Section

Grupo Redutor

Range ChangeSection

2nd speed

1st speed

3rd speed

4th speed

5th speed

6th speed

7th speed

8th speed

Reverse

Posio de vlvulapr-seletoraPreselector valve

position

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

20/96


Sincronizao

A Fig. 1 ilustra o modelo de um conjunto de sin-cronizao ZF, o qual tem a finalidade de equalizaras rotaes. Com isso a mudana de marcha serrpida e segura sem um embreamento duplo namudana para a marcha seguinte, e sem acelera-o intermediria ao reduzir para a marcha anteri-or, mesmo em declives ou situaes difceis.A sincronizao evita o embarao que os moto-ristas possam ter antes de uma mudana de mar-chas. Eles usaro a alavanca de acordo com a ne-cessidade com maior facilidade e de maneira uni-forme, o que muito til no trfego atual.

16

Fig. 1

Synchronization

Fig. 1 shows the construction of a ZF loch

synchroniser. The use of lock synchronising deviceas a speed equaliser will enable the driver to carryout quick safe and noiseless gear changes without double declutching during up changes and alsowithout actuating the accelrator pedal duringdown changes, even on downhill gradients and indifficult situations.

The easier gear changes obtained wita a lock synchrronizer will induce the driver to change gear more frequently. This will improve his drivingtactics,which is of great advantage in today's heavytraffic conditions.

Fig. 1

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

21/96


1. Anel de sincronizao2. Pressionador

3. Corpo de aclopamento4. Corpo de sincronizao5. Luva de engate

Fig. 2

1 2 1

5 1 3

A B C

3 4 5 3

1 - synchronizer ring2 - plunger

3 - clutch body4 - synchronizer body5 - sliding sleeve

17

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

22/96


A Fig. 2 ilustra o funcionamento e o corte do conjunto de sincronizao. O corte e o detalhe A ilus-tram a posio neutro.Ao mover a luva de engate, a partir da posio emneutro para a direita ou esquerda (Na figura, paraa direita) o anel de sincronizao correspondente pressionado pelos pressionadores contra o conede frico do corpo de acoplamento. A diferenade velocidade entre as peas a serem acopladas,faz com que o anel de sincronizao mova-se nosentido radial.Graas a este movimento que limitado por topesde parada, os dentes chanfrados do anel de sincro-nizao so prensados contra os dentes da luva deengate.

Devido a presso persistente sobre a luva e o movi-mento radial do anel de sincronizao e sendo osdentes chanfrados em ambas as peas, produz-se umapresso axial entre os cones de frico do anel desincronizao e o corpo de acloplamento, o que re-duz a diferena entre as velocidades a seremacopladas, efetuando-se assim a sincronizao.

A Fig. 3 ilustra as peas individuais do conjuntode sincronizao.As peas tambm podero ter formas e execu-es diferentes do que as ilustradas na figura.

18

Fig.3

1

2

3

45

6 7

3

21

1. Engrenagem / Gear 2. Corpo de acoplamento / Clutch body3. Anel de sincronizao / Synchronizer ring4. Corpo de sincronizao / Synchronizer body5. Mola / Compression spring6. Pressionador / Plunger 7. Luva de engate / Sliding sleeve

Fig. 2 shows the opreation and a sectional view of the ZF lock synchronizer. Sectional view and part

A show the synchronizer in neutral position.

When the sliding sleeve is moved from neutral position to the left or to he right (illustrationexample shows movement to the right) therespective synchronizer ring is pressed by the

pressure pieces against the friction cone of theclutch body. Due to the existing difference in speed the synchronizer rinf turns immediately in radialdirection until it encounters a stop situated in thesynchronizer body and prevents any further movement of the sliding sleeve.

Due to the persistent pressure in the slidingsleeve

an d the contact pressure of the chamfered selectore teeth the rotational direction of thesynchronizer ring is reversed.

As soon as equalization of ratational speeds isobtained, when there is no longer any friction at work, the sliding sleeve can be moved into the teethof the clutch body. The respective gear is engaged.

Fig. 3 shows the individual components of the ZF lock saynchronizer. The shape and design of thecomponents may differ from those shown in theillustration.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

23/96


INSPEO DOS COMPONENTESLimpar cuidadosamente todas as peas e removeros resduos de massa de vedao das superfciesde contato.

Examinar todas as engrenagens quanto ao estadodos dentes e superfcie de trabalho dos rolamen-tos.

Verificar criteriosamente os roletes e pistas dosrolamentos substituindo em caso de desgaste.

Todos os retentores juntas e aneis-trava deveroser substitudos.

AVALIAO DO SISTEMA DESINCRONIZAAOAntes de montar o conjunto, verificar o desgatedos aneis sincronizadores e dos corpos de engate.

Medir com um calibrador de lminas a distnciaentre a face do corpo e do anel em pelo menosdois pontos opostos.

A distncia (2) dever ser no mnimo de 0,80mm, para as marchas bsicas e split. Para ogrupo planetrio, 1,20 mm.Obs.:Ao encontrar os valores abaixo do especifi-cado, verificar se houve desgaste no anelsincronizador, no corpo de acoplamento ou emambos. Aps verificao, substituir o item cor-respondente, ou o conjunto.

PARTS INSPECTION

Clean the contact surfaces carefully by thoroughly

removing the selaing residual layer.Check all gears, mainly the teeth and bearingsurfaces.

Check accurately the rollers, bearing races and replace them in case of wear.

All selaing rings, gaskets. and circlips must berenewed.

CHECKING WEAR LIMIT

Before assembling the synchronizers, check therings and clutch bodies for wear.

Measure distance between clutch body and synchronizer ring with feeler gauge at two opposite

points.The distance (2) required for the basic gears and

split must be at least 0,80 mm and for the planetary group 1,20 mm.

Note: If the values obtained are under the specified one , verify the wear of the synchronizer ring, onthe clutch body, or both, and replace thecorrespoding item, or the assembly.

1. Calibrador de lminas / Filler gauge2. Distncia mnima em pontos opostos - 0,80mm, para marchas bsicas e split. Para o grupoplanetrio - 1,20 mm / Minimum distance at opposite points for basic gears and split. 80 mmand for the planetary group 1,20mm

3. Anel de sincronizao / Synchronizer ring4. Corpo de acoplamento / Clutch body

1 3

2

4

S5-28

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

24/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

25/96


Vista Explodida eTabela de Componentes

Exploded View and Parts List

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

26/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

27/96


C A I X A D E C

M B I O Z F / Z F G E A R B O X

1 6 S

1 6 5 0

23

I l u s

t r a

o i n f o r m a t

i v a n o v

l i d a p a r a r e s o

l u e s

t c n

i c a s

I n f o r m a t i v e I l l u s t r a t i o n

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

28/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


* C o n

f o r m e a v e r s

o

* D e p e n d i n g o n v e r s i o n

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

29/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

30/96


C A I X A D E C


1 6 S

1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

31/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

32/96


I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


C A I X A D E C


1 6 S 1 6 5 0

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

33/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

34/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

35/96


C A I X A D E C


1 6 S 1 6 5 0

I l u s

t r a

o i n f o r m a t

i v a n o v


l u e s

t c n

i c a s


8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

36/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

37/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

38/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

39/96


3 4 . 1

9 8 . 0

1 0 B u j

o

S c r e w p l u g

3 4 . 1

9 8 . 0

1 0 I n t e r r u p

t o r

S w i t c h

3 4 . 1

9 8 . 0

2 0 A n e

l v e d a

o

S e a l r i n g

4 2 . 0

1 0

E i x o

i n t e r m e d

i r i o

L a y s h a f t

4 2 . 0

2 0

R o l a m . e

s f e r a s

B a l l b e a r i n g

4 2 . 0

3 0

A n e

l e l s t

i c o

L o c k i n g r i n g

4 2 . 0

4 0

B u c

h a

B u s h

4 9 . 1

6 0

M o l a

H e l i c a l s p r i n g

4 9 . 1

8 0

M o l a


4 9 . 2

0 0

M o l a


4 9 . 2

1 0

M o l a


4 9 . 2

2 0

M o l a


4 9 . 3

7 0

A r r u e

l a

W a s h e r

4 9 . 3

9 0

A n e

l V

V R i n g

4 9 . 3

9 0

A r r u e

l a

W a s h e r

4 9 . 4

0 0

M o l a


5 9 . 0

1 0

T e r m

i n a l

R i n g p i e c e

5 9 . 0

2 0 . 0

1 0 P a r a

f u s o o c o

H o l l o w s c r e w

5 9 . 0

2 0 . 0

2 0 A n e

l v e d a

o

S e a l r i n g

5 9 . 0

4 0

T u b o t e c a

l a n

T e c a l a n t u b e

5 9 . 0

4 4

T u b o t e c a

l a n

T e c a l a n t u b e

5 9 . 0

5 0

B r a a

d e i r a

C l a m p

5 9 . 0

5 2

B r a a

d e i r a

C l a m p

5 9 . 0

6 0

S u p o r t e

F i x a t i o n p l a t e

5 9 . 0

7 0 . 0

1 0 P a r a

f u s o

H e x a g o n s c r e w

5 9 . 0

7 0 . 0

2 0 P o r c a

H e x a g o n n u t

8 0 . 0

2 0

V l v u

l a 3 / 2 v i a s

V a l v e

8 0 . 0

3 0

M a n o p

l a

G e a r c h a n g e l e v e r

8 0 . 0

3 2

P o r c a

N u t

8 0 . 0

3 4

A r r u e

l a

W a s h e r

8 0 . 0

4 0

T a m p a

C o v e r

8 0 . 0

5 0

C h a p a

d i s t a n c i a d o r a

S p a c e r S h e e t

8 0 . 0

6 0

T r a m

b u l a d o r c o m p l e t o

S h i f t c o n t r o l

8 0 . 0

6 0 . 5

0 0 C a r c a a

H o u s i n g

8 0 . 0

6 0 . 5

1 0 C r u z e

t a

S p i d e r

8 0 . 0

6 0 . 5

2 0 B u c

h a d e a g u l

h a s

N e e d l e b u s h

8 0 . 0

6 0 . 5

3 0 A r r u e

l a r e

t e n

o

L o c k i n g p l a t e

8 0 . 0

6 0 . 5

4 0 A n e

l d e v e

d a o

S e a l r i n g

8 0 . 0

6 0 . 5

4 4 P e a

d e l i g a

o

C o n n e c t i o n p i e c e

8 0 . 0

6 0 . 5

5 0 P e a

d e l i g a

o

C o n n e c t i o n p i e c e

8 0 . 0

6 0 . 5

7 0 P a r a

f u s o

H e x a g o n s c r e w

8 0 . 0

7 0

A l a v a n c a

G e a r c h a n g e l e v e r

8 0 . 0

8 0

V l v u

l a 3 / 2 v i a s

V a l v e

35

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

40/96


Valores de Ajuste e Torques de Aperto / Adjustment Datas and Tightening TorqueValores de Ajuste em mm: / Adjustment data in mm:Folga axial do rolamento do eixo primrio (pista externa) / Axial clearance of input shaft (outer race) ......... 0 - 0,10Folga axial do rolamento de sada do GP (pista externa) /

Axial clearance of GP output bearing (outer race) ...................................................................... 0 - 0,10Folga axial entre rolamento e anel-trava da rvore secundria /

Axial clearance between bearing and main shaft locking ring .......................................................... 0 - 0,10Folga axial dos rolamentos cnicos do eixo intermedirio /

Axial clearance of layshaft conical bearings ................................................................................. 0,10 - 0,25Folga axial das engrenagens planetrias / Axial clearance of planeteray gears ............................ 0,20 - 0,70Limite de desgaste entre anis de sincronizao e corpos de engate / Wear limit between synchronizer rings and clutch body .......................................................................... 0,80

Folga axial das engrenagens (para fins de controle) / Axial clearance of gears (for control)

1 marcha / 1st speed ...................................................................................................................... 0,20 - 0,502 marcha / 2nd speed .................................................................................................................... 0,20 - 0,653 marcha / 3rd speed ...................................................................................................................... 0,20 - 0,454 marcha / 4th speed ...................................................................................................................... 0,04 - 0,32Do grupo desmultiplicador no eixo primrio ................................................................................. 0,20 - 0,40Intermediria da marcha-a-r / reverse layshaft ............................................................................. 0,20 - 0,50Folga entre os eixos primrio e secundrio / Clearance betwen the input and main shafts .......... 0,60 - 0,90Interferncia do anel bi-partido no eixo primrio / Interference of the split ring on input shaft .......... 0,05Temperatura para montagem das engrenagens do eixo intermedirio (assentos isentos de leo ou graxa) / Temperature for the layshaft gears assembly (seats free from oil or grease) ...................................... 180 CTemperatura para montagem dos rolamentos / Temperature for bearing assembly .................... 100 a 120 C

Temperatura para montagem dos corpos de sincronizao / Assembly temperature for thesynchronizer bodies ............................................................................................................................... 120CInterferncia do anel bi-partido no eixo secundrio / Interference of the split ring on main shaft ....... 0,05

Lubrificantes / LubricantsOs leos recomendados constam na Lista de Lubrificantes TE-ML-02.

All the recommended lubricating oils are listed in the TE- ML-02.

Momento de fora (aperto Nm): / Moment of force (tightening Nm):Parafusos M10 de fixao das carcaas e tampas / Fixing bolts M10 of the housings and covers ............. 49Parafusos (M8) / Screws (M8) ..................................................................................................................... 25Parafusos do flange de sada / Output flange screw .................................................................................. 120Parafuso de fixao do eixo da engrenagem da marcha-a-r / Fixing screw of the reverse gear shaft ..................... 150Conexo do velocmetro / Speedometer connection ................................................................................. 120Parafuso de fixao da engrenagem solar / Fixing bolts of the sun gear .................................................... 49Porcas de fixao dos mbolos de engate / Fixing bolt of the coupling pistons .................................... 160Parafusos de fixao do garfo do GV / GV fork fixing bolts .................................................................... 70Parafusos de fixao do garfo do GP / GP fork fixing bolt ...................................................................... 60Parafusos "ocos" M10 / Hollow screw M10 .............................................................................................. 15Parafusos "ocos" M12 / Hollow screw M12 .............................................................................................. 20Parafusos "ocos" M14 / Hollow screw M14 .............................................................................................. 35Parafusos de fixao do suporte da vlvula solenide / Fixing bolt of the solenoid valve holder. ......... 25

Porca ranhurada do eixo secundrio / Main shaft slotted nut .................................................................. 500Pino roscado do posicionador / Positioner threaded bolt .......................................................................... 45Porca do pino roscado / Threaded bolt nut ................................................................................................ 70

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

41/96


Ferramentas EspeciaisSpecial Tools

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

42/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

43/96


FERRAMENTAS ESPECIAIS /SPECIAL TOOLS

9X56 000 943

9X56 000 863

9X20 500 451Overdrive

9X56 000 944

2

1

3

4

5

N Ferramenta

Tool NumberN Ilustrao / Illustration Denominao / Description

Bucha protetora pararetentores das hastes.

Protector bush for the rodsshaft seals.

9X56 000 866

Ferramenta para remover o

rolamento traseiro do eixointermedirio.

Layshaft rear bearingwtihdrawal

Bucha guia para o rolamen-to do eixo de sada (eixosecundrio).

Guide bush for the output shaft bearing (main shaft).

Dispositivo para ajuste daspastilhas do garfo do split.

Device for adjustment of the split fork pads.

Ferramenta para remover orolamento dianteiro doeixo intermedirio.

Layshaft front bearingwithdrawal .

9X95 100 105Direct drive

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

44/96



9X95 000 014

9X95 000 124

9X56 000 865

9X56 000 855

7

6

8

9

10

N FerramentaTool NumberN Ilustrao / Illustration Denominao / Description

Rgua para medies.

Measurement ruler.9X95 000 242

Colocador do anel bi-partido do eixo primrio.

Input shaft split ringinstaller.

Dispositivo para colocaodos retentores na tampa doGP.

Device for installing theshaft seals on the GPcover.

Mandril para colocao doretentor na tampa do eixo

de mudana.

Mandrel for fitting the shaft seal on the shift shaft cover.

Pressionadores.

Input and main shaftsbearings positoner.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

45/96



9X20 500 008

9X95 000 218

12

11

13

14

15

N Ferramenta


Dispositivo para montagemdo flange de sada.

Mounting tool for theoutput flange.

9X95 000 102

Dispositivo auxiliar(construir).

Auxiliary device(to be manufactured).

Mandril para montagemdos retentores das hastes.

Mandrel for fitting the rodsshaft seals.

Adaptador (usar com9X95 000 102).

Adapter (used inconjunction with9X95 000 102) .

6 0 0 x 1 0

m mM-10

Mandril com cone para colo-cao do retentor do pinhodo velocmetro.

Mandril with cone for fitting the speedometer pinion shaft seal.

9X95 000 106

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

46/96



9X56 000 858

9X56 000 864

9X56 000 85617

16

18

19

N FerramentaTool NumberN Ilustrao / Illustration Denominao / Description

Ganchos de sustentao(M12).

Lifiting device (M12).

Suporte para remoo e

colocao do conjunto dervores na carcaa.

Support for installing and reinstalling the shafts setsin the housing.

Ganchos de sustentao(M18).

Lifiting device (M18) .

9X20 500 439

20

Base para montar pista dorolamento traseiro do eixointermedirio. Usar com9X20 500 260.

Base for installing thelayshaft rear bearingrace.Use with 9X20 500 260.

9X20 500 260Cabo universal (longo)

Universal adaptor (long)

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

47/96



9X95 000 214

22

21

23

N Ferramenta


Mandril para colocao doretentor na tampa decentragem.

Mandrel for fitting theshaft seal on the centeringcover.

9X56 000 867

Chave para porcaranhurada do eixosecundrio

Key for the main shaft slotted nut.

Suporte para remover pistado rolamento do eixoprimrio

Support for removing theinput shaft bearing race.

9X20 500 612

24 9X20 500 489

Mandril para montarrolamentos da 4 marcha.

Mandrel for installing the4th gear bearing.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

48/96


A seguir uma vista geral da sequncia de desmontagem de 1 a 7 e montagem de 7 a 1:

It is showed below a general view of the disassembly sequence from 1 to 7 and the assembly sequence from 7 to 1:

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

49/96


Desmontagem Disassembly

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

50/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

51/96


DESMONTAGEM

Limpar a caixa externamente.Fixar a caixa em um cavalete apropriado ou bancada e drenar

o leo.Remover a tomada de fora, cilindro de engate e eixo deacionamento.

DISASSEMBLY

Clean the gearbox externally.Fasten the gearbox on apropriate support or test bench and drain off the oil.

Remove the power take off, coupling cylinder and drive shaft.

Remover a tubulao de ar, a vlvula de acionamento do GV, aporca de fixao do mbolo e o cilindro.

Remove the air pipe, the GV drive valve, the piston fixing nut and the cylinder.

Remover a tubulao de ar, o cilindro, a porca e o mbolo deacionamento do GP.

Remove the air pipe, the cylinder, the nut and the GP drive piston.

Retirar os parafusos de fixao e o posicionador da haste dogarfo do GP.Remover o GP.

Take off the fixing bolt and the Gp fork rod positioner. Remove the GP.

9X56 000 856

1650-250

16S-27

16S-28

16S-29

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

52/96


Trambulador - Verso Duplo "H"Remover a vlvula de acionamento do GP.

Remote control block - Double "H" Version Remove the GP drive valve.

Remover as tampas lateral e superior e em seguida, remover oanel trava, arruela, mola e a segunda arruela.

Remove the side and upper covers, and then remove the lockingring, washer, spring and the second washer.

Verso Direct DriveDestravar e retirar os parafusos da arruela de encosto e com oextrator universal, sacar a engrenagem solar.

Direct Drive VersionUnlock and remove the screw, thrust washer and with the aid of a universal extractor, drive the sun gear out.

Verso OverdriveRemover os parafusos e a arruela de encosto (1).Remover o anel de segurana (2) e o anel bipartido.

Overdrive Version Remove the screws and the thrust washer (1) Remove the circlip (2) and split ring.

16S-30

1650-201

1650-202

1650-302

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

53/96


Destravar o posicionador, soltar os parafusos da tampa e re-mover o eixo de engate. Em seguida, remover o bloqueio e aslinguetas de arraste.

Unlock the detent plunger, loosen the cover bolts and removethe engagement shaft. Afterwards, remove the block and thedrivers.

Verso "H" SobrepostoRetirar toda a tubulao de ar e a vlvula de acionamento do GP.

Superimposed "H" Version Remove the air line and the GP drive valve.

Remover as tampas lateral e superior.

Remove the side and upper covers.

Remover a tampa com molas, calos, pinos de reteno e pinoda r.Obs.: Para facilitar a desmontagem, comprimir os pinos de

reteno e trav-los com dois pinos de dimetro 5 mm.

Remove the cover with springs, shims. retaining pins and thereverse idler shafts.

Note: To facilitate the disassembly, press the retaining pinsand lock them with two pins of 5mm.

1650-203

1650-204

1650-277

1650-278

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

54/96


Remover a tampa e o eixo de engate.Em seguida remover a tampa do lado oposto.

Remove the cover and the coupling shaft. Afterwards remove the cover on the opposite side.

Remover a vlvula solenide.Em seguida remover o suporte.

Remove the solenoid valve. Afterwards remove the support.

Remover a vlvula 4/2 vias.Em seguida remover o suporte.

Remove the 4/2way valve. Afterwards remove the support.

Soltar a contra porca e remover o parafuso de fixao doposicionador.

Loose the lock-nut and remove the positioner fixing bolt.

1650-279

1650-280

1650-281

1650-282

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

55/96


Retirar os parafusos de fixao do garfo, o retm da haste eremov-la. Retirar o garfo com as pastilhas.

Unscrew the fork fixing bolts, the rod retainer and remove-it. Remove the fork with the pads.

Remover a chapa de segurana e o anel bi-partido.

Remove the tab washer and the split ring.

Retirar os parafusos de fixao e remover a carcaa 1 com 2(dois) ganchos de sustentao n 9X56 000 858.

Unscrew the fixing bolts and remove the housing 1 with 2 (two)with the lifting device 9X56 000 858.

51

Retirar os parafusos da tampa de centragem; coincidir a mar-ca do eixo piloto com a marca da tampa e remov-la.

Unscrew the centering cover bolts; coincide the input shaft

marks with the cover mark and remove it.

16S-39

16S-37

16S-38

8S-10

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

56/96


Fixar o dispositivo 9X56 000 864 no eixo intermedirio e,com o auxlio de um talha, remover o conjunto completo dasrvores com os respectivos garfos.Obs: Em caixas equipadas com interlock pressionar o pino

no furo do posicionador do GP para liberar a passagemdas hastes.

Fasten the device 9X56 000 864 on the layshaft and with theaid of a tackle remove the complete shafts assembly with therespective forks.

Note: In case of gearboxes equipped with interlock press the pin on the hole of the GP positioner to release the rods passage.

Remover a engrenagem da r juntamente com as gaiolas deagulhas e arruela de encosto.

Remove the reverse idler gear together with the needle cagesand thrust washer.

Remover o defletor de leo, anel trava, rolamento, capa dorolamento do eixo intermedirio, filtro e pino interlock.

Remove the oil deflector, locking ring, bearings, layshaft bearing cap, fliter and interlock pin.

52

Retirar o parafuso, remover o eixo, deslocar a engrenagem damarcha-a-r at encostar na carcaa.

Unscrew the bolts, the shaft, displace the reverse gear until it

abuts to the housing.

16S-41

16S

9X56 000 864

8S-19

16S-40

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

57/96


Eixo SecundrioSeparar os eixos primrio e secundrio.

Main ShaftSeparate the input and main shafts.

Fixar o eixo na morsa, destravar e remover a porca ranhuradacom a ferramenta 9X56 000 867.

Clamp the shaft in a vise, unlock and remove the slotted nut with the aid of tool 9X56 000 867.

Com um extrator universal apoiado na luva de engate, remo-ver a engrenagem da 4 marcha junto com um rolamento.Ateno para que os pressionadores no sejam expulsos pelaao das molas.

With the aid of an universal extractor, rested on the slidingsleeve, remove the 4th speed gear together with bearings.Take care that the plungers are not expelled by the springsaction.

Remover o dispositivo e os garfos.

Remove the device and the forks.

1650-302

1650-303

16S-47

9X56 000 867

16S-85

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

58/96


Verso Direct DriveVirar o eixo.Remover a engrenagem da marcha--r juntamente com a pis-ta do rolamento e arruela de encosto.

Direct Drive VersionTurn the shaft.

Remove the reverse idler gear together with the bearing raceand thrust washer.

Remover a engrenagem da 2 marcha juntamente com a pistado rolamento da 1 marcha, o corpo de sincronizao, anelsincronizador e o corpo de acoplamento.Retirar o rolamento de agulhas da engrenagem.

Remove the 2nd speed gear together with the 1st speed bearingrace, synchronizer body, synchronizer ring and the clutch body.

Remove the gear needle bearing.

Remover a engrenagem da 1 marcha juntamente com o corpode engate e a pista do rolamento da marcha--r.Em seguida remover o rolamento de agulhas, corpo deacoplamento e anel sincronizador da 1 marcha, luva de engate epressionadores.Ateno para que os pressionadores no sejam expulsos pela aodas molas.

Remove the 1st speed gear together with the clutch body and the reverse gear bearing.

Afterwards remove the needle bearing, the clutch body and 1st speed synchronizer ring, sliding sleeve and plungers.Take care that the plungers are not expelled by the springs action.

Verso OverdriveRemover a engrenagem da marcha--r juntamente com a en-grenagem solar e pista do rolamento traseiro.Retirar o rolamento de agulhas.

Overdrive Version Remove the reverse gear with the sun gear and the rear bearing race.

Remove the needle bearing.

16S-49

16S-50

8S-22

1650-303

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

59/96


rvore PrimriaRetirar a luva de engate com os pinos retens e as molas.Cuidado para que os pinos no sejam expelidos pela ao dasmolas.

Input shaft Remove the sliding sleeve with the retaining pins and thesprings.Take care that the pins are not expelled by the springs action.

Com a ferramenta 9X20 500 612 e uma prensa, remover apista do rolamento do eixo primrio junto com a engrena-gem, corpo de acoplamento, anel sincronizador e rolamen-to de agulhas.

Using the tool 9X20 500 612 and a press, remove the race of the input shaft bearing with the gear, clutch body, synchronizer and needle bearing.

Bomba de leoRetirar os parafusos e desmontar a bomba de leo.Verificar a folga axial das engrenagens em relao a face dacarcaa que dever ser de 0,07 a 0,10mm.Obs.: A bomba no tem reparo. Em caso de desgaste, substi-

tu-la completa.

Oil pumpUnscrew the bolts and disassemble the oil pump.

Check the gear axial clearance in relation to the housing facethat must be from 0,07 to 0,10 mm. Note: The pump cannot be repaired. In case of wear, renew it

completely.

Virar o eixo a 180 e remover a engrenagem da 3 marcha juntamente com o outro rolamento da 4, corpo de sincroniza-o, anel sincronizador e corpo de acoplamento.Retirar o rolamento de agulhas.

Turn the shaft to 180 and remove the 3rd speed gear together with the other 4th speed bearing, synchronizer body,synchronizer ring and clutch body.Pull the needle bearing out.

16S-54

16S-52

1650-209

9X20 500 612

1650-304

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

60/96


Com a ferramenta n 9X56 000 943 e prensa, remover orolamento.

Remove the bearing using the tool 9X56 000 943 and press.

Remover as engrenagens do eixo uma de cada vez.

Remove the shaft gears one at a time.

Remover o rolamento do lado oposto do eixo intermedirioutilizando a ferramenta n 9X56 000 944.

Remove the bearing from the layshaft opposite side using thetool n 9X56 000 944.

8S-27

8S-28

8S-29

Eixo IntermedirioRemover o anel trava do rolamento.

Layshaft

Remove the bearing locking ring.

1650-251

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

61/96


Remover a carcaa do GP e a engrenagem do sem-fim do ve-locmetro (coroa). Ou conforme a verso, arruela de impulsosdo velocmetro eletrnico.

Remove the GP housing and the speedometer worm (crown).Or depending on the version, the impulse washer of theelectronical speedometer.

Remover a tampa traseira com o rolamento e o eixo do veloc-metro. Ou conforme a verso, transmissor de impulsos do ve-locmetro eletrnico.

Remove the rear cover with the bearing and speedometer shaft,or depending on the version the impulse transmitter of theelectronic speedometer.

Remover o corpo de acoplamento juntamente com o anelsincronizador e a luva de engate.Obs.: Envolver a luva de engate com um pano para evitar

que os pressionadores sejam expulsos pela ao dasmolas.

Remove the clutch body together with the synchronizer ringand sliding sleeve.

Note: Wrap up the sliding sleeve with a cloth to prevent the plungers from falling off by the springs action.

16S-123

16S-124

16S-125

Grupo PlanetrioGPRemover os parafusos, a arruela de encosto e sacar o flangede sada com um extrator universal.

GP -Planetary Groupe Remove the screws, the thrust washer and pull the output flangeout using an universal extractor.

16S-122

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

62/96


Remover o anel trava.A seguir remover o corpo de sincronizao com auxlio de umextrator universal.

Remove the locking ring. Afterwards, remove the synchronizer body with the aid of auniversal extractor.

Remover o anel trava e o rolamento.

Remove the locking ring and the bearing.

Remover o anel trava e o suporte da engrenagem anelar.

Remove the locking ring and the ring gear support.

16S-127

16S-129

16S-128

Com um extrator universal remover o suporte das planetrias.

Remove the planetary support using a universal extractor.

16S-126

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

63/96


Aps retirar os eixos com as buchas elsticas, retirar a engre-nagem com os roletes, arruelas intermedirias e arruelas deencosto.

After removing the shafts with the tension pin, remove the gearswith the rollers,intermediate washers and thrust washers.

16S-131

Introduzir as buchas elsticas totalmente dentro do eixo daplanetria.

Insert the tension pin completely into the planetary shaft.

16S-135

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

64/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

65/96


Montagem Assembly

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

66/96

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

67/96


Eixo SecundrioFixar o eixo em posio vertical.Montar o rolamento de agulhas, engrenagem de 2 marcha,corpo de acoplamento e o anel sincronizador.

Main ShaftFasten the shaft in the vertical position.

Install the needle bearing, 2nd speed gear, clutch body and the synchronizer ring.

Eixo IntermedirioAquecer as engrenagens a 180C e mont-las no eixo.Obs.:1. Certifique-se do correto posicionamento na

prensagem hidrulica.

2. As engrenagens e o eixo devero estar isentos deleo e graxa.

Layshaft Heat the gears to 180 C and install them on the shaft. Note: 1. Make sure if the gears are placed correctly on the

hydraulic press.2. The gears and the shaft must be free from oil and grease.

Aps o resfriamento das peas, montar o rolamento aquecido100 a 120C.Em seguida montar o anel trava.Montar o rolamento do lado oposto do eixo utilizando o mes-mo processo.

After cooling the parts, install the bearings heated to 100 a120 C.

Afterwards, place the locking ring.Using the same procedure install the bearing on the shaft opposite side.

Aquecer o corpo de sincronizao a 120C e mont-lo no eixoobservando a coincidncia dos encaixes entre o corpo e anelsincronizador.

Heat the synchronizer body to 120 C and install it on the shaft observing if the synchronizer body and synchronizer ring are

fitted correctly.

1650-252

1650-253

16S-66

1650-211

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

68/96


Montar a luva de engate.Em seguida montar as molas, os pressionadores, anelsincronizador, corpo de acoplamento, rolamento de agulhas ea engrenagem de 1 marcha.

Install the sliding sleeve. Afterwards install the springs, plungers, synchronizer ring,clutch body, needle bearings and the 1st speed gear.

Aquecer o corpo de acoplamento da marcha-a-r a 120C emont-lo no eixo.Obs.: O lado abaulado dos dentes dever ficar voltado para

cima.

Heat the reverse clutch body to 120 C and install it on theshaft.

Note: The convex side of the teeth must be faced upwards.

Aquecer a bucha do rolamento da 1 marcha 100 a 120C emont-la no eixo.

Heat the 1st speed bearing bush 100 to 120 C and install it on

the shaft.

Verso Direct DriveAquecer a pista do rolamento da engrenagem da marcha-a-r100 a 120C e mont-la no eixo.Em seguida montar o rolamento de agulhas e a engrenagem.

Direct Drive Version Heat the reverse gear bearing race 100 to 120 C and install it on the shaft.

Afterwards, install the needle bearing and the gear.

16S-212

8S-50

16S-69

16S-70

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

69/96


Montar a arruela de encosto com o rebaixo voltado para cima.Em seguida montar a pista do rolamento traseiro aquecida 100a 120C.

Install the thrust washer with the recess faced upwards. Afterwards, install the rear bearing race heated 100 to 120 C.

Virar o eixo a 180, montar o rolamento de agulhas, engrena-gem da 3 marha, corpo de acoplamento e anel sincronizador.

Turn the shaft to 180 , install the needle bearing, 3rd speed gear, clutch body and the synchronizer ring.

16S-71

8S-51

Verso OverdriveMontar a engrenagem da r e rolamento de agulhas.Aquecer a engrenagem solar de 100 a 120C e mont-la narvore secundria.

Overdrive Version Install the reverse gear and the needle bearing. Heat the sun gear from 100 to 120C and install it on themain shaft.

16S-290

16S-291

Montar a pista do rolamento traseiro.

Install the rear bearing race.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

70/96


Montar a engrenagem da 4 marha com a face gravada (L. Mo-tor) voltada para cima.Em seguida montar o 2 rolamento no sentido inverso ao 1rolamento.

Install the 4th gear with the engraved face (engine side) facingupwards.

Afterwards install the 2nd bearing in the opposite direction tothe 1st bearing.

1650-254

1650-303

Montar a porca ranhurada e com a ferramenta 9X56 000 867,apert-la com 500 Nm.Em seguida, travar a porca.

Place the slotted nut and with the aid of tool 9X56 000 867,tighten it to a torque of 500Nm.

Afterwards lock the nut.

9X56 000 867

1650-213

16S-292

Aquecer o corpo de sincronizao a 120C e mont-lo no eixoobservando a coincidncia de encaixe entre corpo e anelsincronizador.

Heat the synchronizer body to 120 C and install it on the shaft observing if synchronizer body and the synchronizer ring are

fitted correctly.

Montar o 1 rolamento na rvore, com a salincia da pista in-terna voltada para cima.Em seguida montar a luva de engate, molas e pressionadores,anel sincronizador e corpo de acoplamento da 4 marcha.

Install the 1st bearing on the shaft, with inner race salience facing upwards. Afterwards, install the sliding sleeve, springs and plungers,synchronizer ring and 4th speed clutch body.

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

71/96


Montar o rolamento da rvore secundria na carcaa e fix-locom o anel trava.Obs.: O anel-trava poder ter uma folga de 0,10 mm.Em seguida prensar um novo defletor de leo sobre o rola-mento com a aba voltada para cima.

Install the main shaft bearing on the housing and fasten it with the locking ring.

Note: The locking ring can have a clearance of 0,10 mm. Afterwards, press a new oil deflector on the bearing with theconvex edge faced upwards.

Aps posicionar a engrenagem com as gaiolas de agulhas aque-cer a pista interna do rolamento 100 a 120C e mont-la noeixo at encostar.

After positioning the gears with the needle cages heat thebearing outer race 100 to 120 C and install it on the shaft until its abuts.

Posicionar a luva de engate com molas novas e retens. Levan-tar a luva at que os retens se encaixam nos rebaixos da mes-ma e baix-la novamente encaixado assim os trs retens deuma s vez.

Position the sliding sleeve with new springs and retaining rings. Lift the sliding sleeve until the retaining rings fit on its recessand lower it again fitting the three retaining ringsautomatically.

16S-75

16S-77

Eixo PrimrioPosicionar o anel sincronizador e o corpo de acoplamentono eixo.

Input ShaftPosition the synchronizer ring and the clutch body on the shaft.

16S-73

16S-74

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

72/96


9X20 500 451

9X95 100 105ou / or

68

Montar o rolamento do eixo primrio na carcaa dianteira efix-lo com a ferramenta 9x95 000 014.

Install the input shaft bearing in the front housing and fastenit with the tool 9X95 000 014.

Medida "A"Virar a carcaa e introduzir o eixo primrio at o completoassentamento no rolamento e proceder a medida "A" comosegue:Colocar uma junta nova na face de assentamento da carcaadianteira e medir a distncia entre a face da carcaa e o rebai-xo do corpo de acoplamento.Obs.: Medir em dois pontos opostos e anotar o valor mdio.

Subtrair a espessura da rgua.

Measurement A Turn the housing and insert the input shaft until it fitscompletely in the bearing and proceed the measurement Aas follows:Place the new gasket on the front housing seat face and measure

the distance between the housing face and the clutch bodyrecess.

Note: Measure at two opposite points and record the averagevalue. Substract the ruler thickness.

Instalar a bucha-guia 9X95 100 105 ou 9X20 500 451 e umdispositivo auxiliar no eixo secundrio e introduzi-lo na car-caa em posio vertical at o completo assentamento.

Install the guide bush 9X95 100 105 or 9X20 500 451 and anauxiliary device on the main shaft and insert it in the housingin vertical position until it fits completely.

16S-78

16S-80

Montar a pista do rolamento traseiro do eixo intermedirio ato completo assentamento.Usar a ferramenta 9X20 500 439 em conjunto com a 9X20 500 260.

Install the layshaft rear bearing race until it fits completely.Use the tool 9X20 500 459 in conjunction with the 9X20 500 260.

1650-255

9X20 500 260

9X20 500 439

8S-63

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

73/96


Posicionar a mola com o pino "interlock".

Position the spring with the interlock pin.

Apoiar o anel escolhido no corpo do acoplamento e removernovamente os eixos das respectivas carcaas.

Rest the selected ring on the clutch body and remove the shaftsof the respective housings again.

Posicionar a engrenagem intermediria da marcha-a-r, comrolamentos de agulhas e arruela de encosto.

Position the reverse intermediate gear, with the needle bearingsand the thrust washer.

16S-49

16S-43

1650-220

Medida "B"Medir a distncia entre a face da carcaa e a face plana dodente da engrenagem da 4 marcha.Obs.: Medir em dois pontos opostos e anotar o valor mdio.

Subtrair este valor da espessura da rgua.Efetuar o clculo A-B.O calo dever ter no minmo 0,6mm e no mximo 0,9 mmmenor que o valor encontrado.

Measurement B Measure the distance between the housing face and the flat face of the 4th speed gear tooth. Note: Measure at two opposite points and record the average

value. Subtract the obtained value from the ruler thickness.

Calculate A-B

The shim must be with min. 0,6 mm and max. 0,9 mm less thanthe value obtained.

1650-256

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

74/96


Colocar a bucha-guia 9X95 100 105 ou 9X20 500 451 na parte trasei-ra do eixo secundrio e com o auxlio de uma talha, introduzir o con-

junto na carcaa, observando o encaixe das hastes de engate.Aps o completo assentamento do conjunto, retirar o dispositivo.Obs.: Em caixas equipadas com "Interlock", comprimir o pino

durante a montagem , a fim de liberar a passagem dashastes.

Place the guide bush 9X95 100 105 or 9X20 500 451 on the rear part of the main shaft and with the aid of a tackle, insert theassembly into the housing, observing if the gearshift rods fit accordingly.

Remove the device if the assembly is fitted completely. Note: In case of gearboxes equipped with interlock press the

pin during the assembly, in order to release the rods passages.

Centralizar a engrenagem da marcha-a-r e montar o eixo como rebaixo voltado para o lado do parafuso trava.Colocar a arruela, roscar e apertar o parafuso com 150 Nm.

Center the reverse gear and install the shaft with the recess faced to the locking screw.Place the washer, screw up and tighten the screw with 150 Nm.

Unir os trs eixos e posicionar os garfos de engate com aspastilhas.Instalar a ferramenta 9X56 000 864.

Join the three shafts and position the gearshift forks with thesliding pads.

Install the tool 9X56 000 864.

16S-70

16S-86

Posicionar o rolamento de rolos no eixo e un-lo ao eixosecundrio.

Install the roller bearing on the shaft and join it.

1650-206

16S-85

9 X 5 6

0 0 0 8

6 4

9X95 100 105ou / or

9X20 500 451

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

75/96


Montar o filtro na carcaa.Em seguida montar uma junta nova.

Install the filter in the housing. Afterwards fit a new gasket.

Deslocar a luva totalmente para baixo e fixar o dispositivo9X56 000 683 junto com a arruela de 6 mm na carcaa e aper-tar a porca o suficiente para a que a haste fique sem folgaaxial, porm possa permitir um movimento radial.

Displace the sliding sleeve completely downwards,fix thedevice 9X56 000 683 together with the washer of 6mm on thehousing and tighten the nut enough until the rod is without axial clearance, thus allowing a radial movemnet.

Regular a posio axial do garfo atravs dos parafusos allen.Nota: Um parafuso tem a funo de baixar a posio do garfo

e o outro a de levantar.Apertar alternadamente os parafusos de forma a manter aspastilhas centradas na luva de engate, ou seja: - Com folgaigual em ambos os lados. Aps a regulagem, apertar os para-fusos com 70 Nm e retirar o dispositivo.

Adjust the axial position of the fork by means of Allen bolts Note: One screw lowers the position of the fork and the other

lift it.Tighten the screws alternately keeping the sliding pads centered

in the sliding sleeve, i.e: with equal clearance in both sides. After the adjustment, tighten the screws with 70 Nm and remove the device.

16S-89

16S-90

16S-91

Montar o garfo com as pastilhas na luva de engate do GV,introduzir a haste na carcaa e no garfo e fix-la provisoria-mente com um parafuso.

Install the fork with the sliding pads on GV sliding sleeve,insert the rod into the housing and into the fork and fasten it with a screw temporarily.

16S-39

9X56 000 683

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

76/96


Eliminar a folga do rolamento e montar o bi-partido com aferramenta n 9X56 000 855.Obs.: Valor de ajuste de anel: 0,05 mm

Eliminate the bearing clearance and install the split ring withthe tool nr. 9X 56 000 855.

Note: Ring adjustment value: 0,05 mm.

Montar um novo anel de segurana sobre o bi-partido e trav-lo em 4 pontos equidistantes.

Install a new retaining ring on the split ring and lock it at 4equidistant points.

Montar arruela de encosto do rolamento com o chanfro volta-do para cima.

Install the bearing thrust washer with the chamfer faced upwards.

16S-93

16S-94

16S-95

9 X 5 6 0 0

0 8 5 5

Montar a capa externa do rolamento do eixo intermedirio nacarcaa II.Em seguida montar a carcaa II sobre I observando o encaixedas hastes dos garfos.

Apertar os parafusos com 49Nm

Install the outer cap of the layshaft bearing on the housing II. Afterwards install the housing II on the I one and make sure if the rods of the gearshift forks are fitted correctly.Tighten the screws with 49Nm.

16S-38

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

77/96


Medir a distncia da face da carcaa at a pista do rolamento.Acrescentar a esse valor a espessura da junta.O calo dever ser de 0,10 a 0,25 mm menor que o valor en-contrado.

Measure the distance from the housing face to the bearingrace.

Add to this value the gasket thickness.The shim must be from 0,10 to 0,25 mm less than the valueobtained.

Com a ferramenta n 9X95 000 214, montar o retentor na tam-pa de centragem.

Install the shaft seal on the centering cover, using the the tooln 9X95 000 214.

16S-96

9X95 000 214

Posicionar o pino-guia da bomba com o furo da tampa decentragem.

Position the pump guide pin with the centering cover bore.

8S-77

8S-78

73

Folga Axial do Eixo IntermedirioCom um martelo e um saca pino, bater levemente na pistaexterna do rolamento do eixo intermedirio at eliminar a fol-ga dos roletes.

Layshaft Axial ClearanceWith the aid of a hammer and a soft drift, blows lightly on thelayshaft bearing outer race until the rollers axial clearance iseliminated.

8S-74

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

78/96


Medida "B"Medir a distncia da face do rolamento at a face da carcaa.Subtrair A-B.O valor encontrado ser o valor do calo.O calo a ser utilizado poder ser at 0,10mm menor que ovalor encontrado.Selecionar o calo que proporcione a menor folga possvel.

Measurement B Measure distance from the bearing face to the housing face.Substract A-B.The value obtained will be the shim value.

The shim to be used can be up to 0,10 mm less than the valueobtained.Select the shim with the least axial clearance if possible.Montar a tampa de centragem na carcaa.Obs.:Antes da montagem, posicionar o canal da engrenagem

interna da bomba na direo do canal livre da tampa damesma, para permitir a passagem do pino de arraste(vide desmontagem).

Apertar os parafusos com 49Nm.

Install centering cover on the housing. Note: Before disassembling it, position the inner gear channel

of the pump in the direction of its cover free channel, toallow the passage of the detent pin (See Disassembly).

Tighten the screws with 49Nm.

Montagem da Tampa de CentragemMedida "A"Medir a distncia da face da tampa at o alojamento da pistaexterna do rolamento do eixo primrio.Adicionar a esta medida a espessura da junta.

Centering cover assembly Measurement "A" Measure distance from the centering cover face to the outer race of the input shaft bearing location.

Add to this measurement the thickness of the gasket.

16S-100

16S-99

16S-101

Aps a montagem da bomba apertar os parafusos com 6,0Nm.

After installing the pump tighten the screws with 6,0Nm.

1650-221

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

79/96


Trambulador - Verso duplo "H"Com a ferramenta n 9X95 000 124, montar os retentores in-terno e externo na tampa lateral.

Remote control block - Double "H" Version Mount the inner and the oute r shaf t seals on the sidecover using the tool nr. 9X95 000 124.

Posicionar a tampa no eixo de engate, arruela de encosto como rebaixo voltado para o anel e o prprio anel.Em seguida posicionar os pinos de engate.Ateno: Posicionar os pinos de engate com graxa, paraevitar que os mesmos caiam para dentro da caixa durante amontagem.

Position the cover on the coupling shaft, thrust washer withthe recess faced to the ring and the ring.

Afterwards position the coupling pin. Attention: Position the coupling pins with grease, so as to prevent them from falling into the housing during the assemblyoperation.

8S-83

8S-84

9X95 000 124

Verso Direct DriveMontar arruela de encosto do rolamento do eixo secundriocom o chanfro voltado para fora.Montar a engrenagem solar aquecida a 120C.

Montar a arruela de encosto com tubo de lubrificao e apertaros parafusos com 49Nm, travando-os em seguida com arame.

Direct Drive Version Install the thrust washer of the main shaft bearing with thechamfer faced outside.

Install the sun gear heated to 120C. Install the thrust washer with the lubricating pipe and tighten thescrews to a torque of 49 Nm, afterwards, lock them with wire. 16S-102

Verso OverdriveMontar o anel bi-partido e o anel de segurana (1) do rola-mento traseiro. Em seguida, travar o anel de segurana.Montar a arruela de encosto (2) com tubo de lubrificao eapertar os parafusos com 49 Nm, travando-os em seguida comarame.

Overdrive Version Mount the split ring and the rear bearing circlip (1) and thenlock it.

Mount the thrust washer (2) with the lubricating pipe and tighten the screws to 49 Nm. Then lock them with wire.

1650-305

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

80/96


Pinos de 5 mmPins of 5 mm

76

Posicionar na carcaa o posicionador com as molas e os pinosde reteno.

Position in the housing the detent segment with the springsand the detent segment.

Posicionar as peas de bloqueio e as linguetas de arraste, ob-servando a sequncia numrica.

Position the interlock parts and driver.Pay attention to the numerical order.

8S-87

8S-88

Comprimir os pinos de reteno e trav-los com 2 pinos dedimetro de 5mm.

Press the retaining pins and lock them with 2 pins of 5mm.

16S-105

Posicionar os pinos de reteno com as molas nos alojamentos.

Position the retaining pin with the springs in the locations.

8S-85

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

81/96


Montar a arruela centralizadora, a mola, a outra arruelacentralizadora e anel trava.Em seguida montar a tampa com nova junta e apertar os para-fusos com 25 Nm.

Install the centering disc, spring, the other centering disc and locking ring.

Afterwards, install the cover with new gasket and tighten thescrews to a torque of 25Nm.

Posicionar os pinos de reteno com as molas e em seguida opino da r.

Position the retaining pins with the springs and after that thereverseidler shaft.

1650-258

8S-08

Pressionar o posicionador com uma alavanca, colocar o para-fuso de fixao e apert-lo com 50 Nm.Em seguida trav-lo com a porca.

Press the detent plunger with a lever, place the fixing screwand tighten it to a torque of 50Nm.

Afterwards lock it with a nut.

1650-257

Posicionar uma nova junta na tampa e montar o eixo de engate.Obs.: Colocar os parafusos na tampa mas no apert-los

ainda.

Position a new gasket on the cover and install the couplingshaft.

Note: Place the screws on the cover without tightening them.

16S-223

8/10/2019 ZF_16S-1650_double_H___0091_765_008_a_2005.pdf

82/96


Montar a tampa com a nova juntaEm seguida colocar os parafusos e apert-los com 25 Nm.

Install the cover with a new gasket. Afterwards place the screws and tighten them to a torque of 25Nm.

1650-225

78

1650-260

Montar a vlvula de acionamento do GP com novo anel devedao.Colocar parafusos com arruelas e apert-los com 25 Nm.

Install the GP drive valve with the new sealing ring.Place the screws with the washers and tighten them to a torqueof 25Nm.

1650-283

Verso "H"SobrepostoMontar o conjunto de lingueta de arraste na carcaa, obser-vando a seqncia numrica.Obs.: Montar a lingueta (n 1) de encosto com o rebaixo

voltado para fora (lado do anel elstico).

Superimposed H version Install the driver set in the housing, checking if the numericalsequence is correct.

Note: Install the driver (nr.1) with the recess faced outward.(on the snap ring side).

Posicionar na tampa as trs molas, os calos e a junta.Em seguida montar a tampa, os parafusos e apert-los com 25 Nm.Apertar tambm os parafusos da tampa do eixo de engate.

Install on the cover the three springs, the shims and the gasket. Afterwards install the cover, the screws and tighten them to atorque of 25Nm.Tighten the co

zf_16s-1650_double_h___0091_765_008_a_2005.pdf

Documents