8HP55A

Reparaturanleitung
Repair Manual
Manuel de Réparation
Manual de Reparaciones
Manuale di Riparazione
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8 HP 55 A
Car Automatic-Transmission
ZF
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ZF
subject to alterations.
© Copyright 2014, all rights reserved and published by

ZF Friedrichshafen AG, ZF Services, S aarbrücken, Department MAPS14
No part of this document may be copied or transferred for any purpose without the
express consent of ZF Friedrichs hafen AG, Saarbrücken regardless of how this is
done or by what means, either mechanical or el ectrical.
Printed in Germany.
Contents
Preliminary information IV
1. General 1.1/1
1.1 Illustration of transmission 1.1/1
1.2 Power flow diagram 1.2/1
1.3. Screw connection specifications 1.3/1

1.3.1 Mechatronic unit types M and E 1.3/1
1.3.2 Oil pan 1.3/1
1.3.3 Differential cover 1.3/1
1.3.4 Distribution housing 1.3/2
1.3.5 Intermediate housing 1.3/2
1.3.6 Converter housing 1.3/2
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1.3.7 Oil supply 1.3/3
1.3.8 Intermediate plate 1.3/3
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1.3.9 Guide plate 1.3/3
1.4 Adjustment work 1.4/1

1.4.1 Measuring multidisk package
1.4.2 Clutch D air clearance adjustment
1.4.3 Clutch C air clearance adjustment
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1.4/3
1.4/7
1.4.4 Clutch E air clearance adjustment 1.4/11
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1.4.5 Brake A air clearance adjustment 1.4/15
1.4.6 Brake B air clearance adjustment 1.4/19
1.4.7 Switch adjustment (locking spring) 1.4/23
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1.4.8 Bevel gear (front axle differential) 1.4/25

1.4.8.1 Pinion position 1.4/25
1.4.8.2 Pinion shaft bearing design height 1.4/26
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1.4.8.3 Regulations for the adjusting washer for the pinion shaft bearing 1.4/28
1.4.8.4 Crown gear position torsional clearance 1.4/29
1.4.8.5 Differential prestressing 1.4/30
1.4.9 Transmission clearance and front axle output 1.4/32
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1.5 Tightening torques 1.5/1
1.6 Transmission test 1.6/1
1.7 Special tools 1.7/1
1.8 Oil flow diagram 1.8/1

1.8.1 DIN schematic E26/4 1.8/1
14/11/21 8 HP 55 A I
2. Dismantling 2.1/1
2.1 Preparations 2.1/1

2.1.1 Drain transmission oil 2.1/1
2.2 Transmission clearance and front axle output 2.2/1

2.2.1 Remove and dismantle distribution housing 2.2/1
2.2.2 Remove intermediate housing and dismantle front axle output 2.2/3
2.2.3 Dismantle front axle shaft 2.2/7
2.2.4 Dismantle output gear 2.2/9
2.2.5 Dismantle drive wheel 2.2/10
2.2.6 Dismantle side shaft 2.2/11
2.3 Remove flanged shaft, front axle differential and converter 2.3/1
2.3.1 Remove anged shaft and front axle differential 2.3/1
2.3.2 Dismantle anged shaft 2.3/3
2.3.3 Remove converter 2.3/4
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2.3.4 Remove converter housing 2.3/5
2.3.5 Dismantle converter housing 2.3/6
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2.3.6 Remove pinion shaft 2.3/8
2.3.7 Dismantle pinion shaft 2.3/9
2.4
2.4.2 Remove mechatronic unit

2.4.3 Remove parking lock
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Remove oil pan, mechatronic unit and parking lock
2.4.1 Remove oil pan and oil lter
2.4/1
2.4/1
2.4/1
2.4/6
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2.5 Remove and dismantle oil supply 2.5/1
2.5.1 Remove oil supply 2.5/1
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2.5.2 Dismantle oil supply 2.5/1
2.6 Remove and dismantle tower 2.6/1

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2.7 Remove clutches 2.7/1

2.7.1 Remove clutch E 2.7/1
2.7.2 Remove clutch C 2.7/1
2.7.3 Remove clutch D 2.7/2
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II 8 HP 55 A 14/11/21
3. Assembly 3.1/1
3.1 Preparations 3.1/1

3.1.1 Install parking lock and gearshift 3.1/3
3.2 Kupplungen montieren 3.2/1

3.2.1 Clutch D 3.2/1
3.2.2 Clutch C 3.2/4
3.2.3 Clutch E 3.2/6
3.3 Assemble tower and oil supply 3.3/1

3.3.1 Assemble tower 3.3/2
3.3.2 Assemble oil supply 3.3/9
3.3.3 Assemble brake A 3.3/12
3.3.4 Assemble brake B 3.3/14
3.4 Install tower and oil supply in transmission 3.4/1
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3.4.1 Install tower 3.4/1
3.4.2 Install oil supply 3.4/3
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3.5 Assemble mechatronic unit and oil pan 3.5/1
3.5.1 Install mechatronic unit 3.5/1
3.6
3.5.2 Install oil pan
Complete and install converter housing

3.6.1 Complete differential cover
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3.6/1
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3.6.2 Complete and install pinion shaft 3.6/2
3.6.3 Complete converter housing 3.6/3
3.6.4 Install differential in converter housing 3.6/5
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3.6.5 Pre-assemble anged shaft 3.6/7

3.6.6 Install converter housing on transmission housing 3.6/8
3.6.7 Install converter and anged shaft 3.6/9
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3.7 Assemble front axle output 3.7/1

3.7.1 Complete intermediate housing 3.7/1
3.7.2 Prepare transmission housing, assemble side shaft 3.7/2
3.7.3 Complete drive wheel 3.7/4
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3.7.4 Complete output gear 3.7/6

3.7.5 Complete front axle shaft 3.7/6
3.7.6 Assemble drive wheel. front axle shaft and output gear 3.7/7
3.8 Assemble rear axle output 3.8/1

3.8.1 Prepare and assemble distribution housing 3.8/1
3.8.2 Complete and assemble the rear axle output 3.8/3
Revisions XI
14/11/21 8 HP 55 A III
Preliminary information
This manual contains the procedure for repairing the complete transmission.
The repair manual is only readily comprehensible if it is backed by ZF-Services training. Failure to
follow the manual may result in incorrect installations.
All dismantling and assembly work must be carried out in chronological order.
The photographs have been kept general for the various applications and are not binding in all cases.
Major modifications for specific applications which must be taken into consideration in the repair
work are published in Technical Bulletins and training courses.
The specifications and information from SDM and Serviceline must be used for the repair work. See
also the maintenance recommendations for the list of lubricants for automatic transmissions.
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Please note the following:
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• Seals such as O-rings, shaft sealing rings and filters must generally be replaced.
• A thin coating of Vaseline must be applied to all O-rings, rectangular rings and other sealing
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rings or with a film of transmission oil before installation. Metal seals must be fitted dry and
without any grease.
• All bearings must be installed with a light coating of oil.
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• Lining and steel disks may be replaced or reused depending on their condition.
• After clutches/brake have been damaged the converter, oil pipes and oil cooler must be tho-
roughly and adequately cleaned with a suitable cleaning product.
• Aluminum screws must always be replaced.
ZF
The following conditions should be satisfied before starting the repair work:
• The required special tools must be available (see section 1.7), otherwise incorrect assembly
is possible.
• A suitable transmission test bed must be available.
The required test values are set out in the Technical Bulletins.
IV 8 HP 55 A 14/11/21
The mechatronic unit is described in this manual as a complete unit and should not be dismantled
by personnel without special skills but should be replaced in full.
A separate manual is planned for the mechatronic unit.
Important
The transmission is filled with oil for its full service life.
The oil only has to be replaced after the vehicle has covered between 80,000 km and 120,000
km, depending on the drive conditions, or after 8 years. (see ref. TE-ML 11)
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The transmission may only be delivered with the oil volume and type set out in the relevant parts
in
lists document (see SDM).
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Technical After-Sales Technical Documentation After-Sales Workshop
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Herth Reus Stubauer

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14/11/21 8 HP 55 A V
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1. General
1.1 Illustration of transmission
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14/11/21 8 HP 55 A 1.1/1
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1.2 Power flow diagram
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14/11/21 8 HP 55 A 1.2/1
Transmissionn ratio
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1.2/2 8 HP 55 A 14/11/21
1.3. Screw connection specifications
1.3.1 Mechatroni c unit types M and E

NOTICE
Use the assembly sequence set out in
19 specification 1087.700.079.
13
17
12 See section 1.5 for tightening torques.

14
11
18
10
Tighten 19 screws on mechatronic unit in
9
2
4
15 following order:
1 3
8 5
1  2  3  ...  19
6
16
7
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1.3.2 Oil pan
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NOTICE
eL specification 1087.700.272.
See section 1.5 for tightening torques.

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Tighten 12 screws on oil pan in fol-
lowing order:
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1  2  3  ...  12
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1.3.3 Differential cover

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NOTICE
specification 1084.700.007.
Tighten 11 screws on intermediate

housing in 2 stages:
Sequence Screw Tightening torque
1 10, 5 4,0 ± 1,0 Nm

2 1 - 11 27,0 ± 2,7 Nm
Special feature: Screw 10 with coating
14/11/21 8 HP 55 A 1.3/1
1.3.4 Distribution housing
NOTICE
Tighten 6 screws on distribution housing

in following order:
1  2  3  ...  6
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1.3.5 Intermediate housing
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NOTICE
Tighten 15 screws on intermediate

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housing in 3 stages:
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1 6, 10 6,0 ± 1,0 Nm
2 1 - 11 10, 0 Nm + 90°
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± (1,0 Nm + 5°)
3 12 - 15 47, 0 ± 4,7 Nm
1.3.6 Converter housing

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NOTICE
Use the assembly sequence set out in 10
11
specification 1087.700.081. 9
2 12
Tighten 15 screws on converter housing

in 3 stages: 13
8
7 1
1 1, 2 9,0 ± 1,0 Nm 6 3
2 1 - 14 9,0 Nm + 60°
5 4 14
± (1,0 Nm + 5°) 15
3 15 16,0 Nm
1.3/2 8 HP 55 A 14/11/21
1.3.7 Oil supply
NOTICE
11 12
10 Use the assembly sequence set out in
13
9 specification 1084.700.163.
14
8 See section 1.5 for tightening torques.
2
1 3 Tighten 14 screws on distribution housing

in followi ng order:
7
1  2  3  ...  14
6
5 4
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1.3.8 Intermediate plate
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NOTICE
2
3
eL specification 1090.700.133.

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Tighten screws on oil supply in the
following order:
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5 1
6 4 1  2  3  ...  5
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1.3.9 Guide plate

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NOTICE
Tighten guiding plate screws according

to tables:
1 3 Tur n in, 2- 4 turns
2 1 -3 10,0 Nm (± 1,0 Nm)
14/11/21 8 HP 55 A 1.3/3
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1.4 Adjustment work
1.4.1 Measuring multidisk package
Place the 2 spacers 5p01.000.329 on

marked points on measuring device
5p01.000.330.
98009
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Use the knurled screw to turn adjusting
fixture 5p01.001.458 to the upper limit
position.
eL Attach strain gauge 5p01.000.329 in the
adjusting fixture.
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98011
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Tighten the 4 knurled screws

5p01.000.329 to secure the adjusting
fixture firmly with the height measuring
fixtures by way of the spacers.
Connect measuring plate 5p01.040.330 to

the strain gauge with the locating pin.
Clamp the disk cluster to be measured

into the fixture, using the knurled screw
(the corrugated steel disk, if present,
must be at the bottom).
98012
14/11/21 8 HP 55 A 1.4/1
Check value on display of force
measuring unit.
98017
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Place measuring beam 5p01.000.330 on
measuring plate.
Place measuring foot of dial gage in

groove in measuring plate on topmost
disk in multidisk package.
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Set dial to zero.
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98018
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Move measuring beam down to base

plate.
Read measurement  MX*
*Index X stands for inserted multidisk

package from clutches/brakes. (A, B, C,
D, E)
1.4/2 8 HP 55 A 14/11/21
1.4.2 Clutch D air clearance adjustment
(Adjustment specification 1087.700.135)
Multidisk package consists of following:

a coil spring followed by, alternately:
external disk > lining disk and finally an
end disk.
10187
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Place multidisk package into measuring
unit, prestressing force = 200 N.
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pressure plate of measuring unit.
Position on measuring sensor on base

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plate and set dial gage to "0".
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Carry out measurement on multidisk

package.
Read measurement
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 M DLP = 20.46 mm
10188
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MDLP
20.46
F F = 200 N +/- 5 N
14/11/21 8 HP 55 A 1.4/3
Place measuring beam with dial gage on
cylinder D.
Place measuring sensor on piston D.
Set dial gage to "0" and find dimension

to top of the snap ring groove.
10184
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Repeat measurement at 3 places and find
measurements.
M1 = 21.97 mm,
M2 = 21.96 mm;
M3 = 21.96 mm
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Average value
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 MDSR = 21.96 mm
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21.96 10186
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MDZYL
MDLS
Thickness of measuring sensor

MMT = 1.80 mm
MDZYL = M DSR + M MT
MDZYL = 21.96 + 1.80 [mm]
MDZYL = 23.76 mm
MD = M DZYL - M DLP
MD = 23.76 - 20.46 [mm]
MD = 3.30 mm
1.4/4 8 HP 55 A 14/11/21
Thickness of snap ring:
MDSP = 1.8 mm
Air clearance:
MDLS Act = M D - MDSP

MDLS Act = 3.3 - 1.8 [mm]
MDLS Act = 1.50 mm
Adjustment specification 1087.700.135

(fitted with 4 lining disks)
MDLS Des = 1.33 to 1.62 mm
 Snap ring thickness MDSP with 1.8 mm

= OK.
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14/11/21 8 HP 55 A 1.4/5
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1.4.3 Clutch C air clearance adjustment

end disk.
 MCEL: 3.6 mm
10180
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Place multidisk package (without end
disk) into measuring unit, prestressing
force = 200 N.
pressure plate of measuring unit.
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package.
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Read measurement
10181  MCLP = 26.,31 mm
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MCLP
26.31
F F = 200 N +/- 5 N
14/11/21 8 HP 55 A 1.4/7
Assemble cylinder C with end disk and
secure it with old snap ring.
Use height gage to find dimension from

top of the end disk to support of the disk
toothing.
10182
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Read the measurement 
MCZYL = 28.507 mm
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28.507
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10183
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MCZYL
1.4/8 8 HP 55 A 14/11/21
MCLS Air clearance:
MCLS Act = MCZYL - MCLP

MCLS Act = 28.507 - 26.31 mm
MCLS Act = 2.197 mm

MCLS Des = 1.90 to 2.40 mm
 End disk M CEL with 3.6 mm = OK.
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14/11/21 8 HP 55 A 1.4/9
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1.4.4 Clutch E air clearance adjustment

end disk 3.3 mm).
 MEEL: 3.3 mm
10180
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Place Multidisk package (without end disk)
into measuring unit, prestressing force =
200 N.
pressure plate of the measuring unit.
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package.
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Read measurement
10177  MELP = 21.67 mm
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MELP
21.67
F F = 200 N +/- 5 N
14/11/21 8 HP 55 A 1.4/11
Assemble cylinder E with end disk and
secure it with old round wire ring.
Use height gage to find the dimension

from top of the end disk to support of the
disk toothing.
10178
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Read measurement
 MEZYL = 23.75 mm
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23.75
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10179
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MEZYL
1.4/12 8 HP 55 A 14/11/21
M ELS Air clearance:
MELS Act = MEZYL - M DSP

MELS Act = 23.75 - 21.67 mm
MELS Act = 2.08 mm

MELS Des = 1.56 to 2.05 mm
 End disk M EEL with 3.3 mm

= Inadequate.
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New end disk with a thickness of 3.6 mm
Read the measurement

eL  MELP: = 21.97 mm
MELS Act = 23.75 - 21.97 mm

MELS Act = 1.78 mm
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 End disk M EEL with 3.6 mm = OK
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14/11/21 8 HP 55 A 1.4/13
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1.4.5 Brake A air clearance adjustment

end disk.
10170
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package.
Read measurement
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 MALP = 20.78 mm
10171
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MALP
20.78
F F = 200 N +/- 5 N
14/11/21 8 HP 55 A 1.4/15
piston B. Place measuring sensor on pist on
A. Set dial gage to "0" and find dimension
to the top of the snap ring groove.
Repeat measurement at 3 places and find

measurements.
M1 = 23.00 mm,
M2 = 23.02 mm,
M3 = 23.03 mm
Average value
 MASR = 23.02 mm
10172
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23.02 MAZYL
Measuring sensor thickness:

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MMT = 1.80 mm
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MAZYL = M ASR + M MT
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MAZYL = 23.02 + 1.8 [mm]

MAZYL = 24.82 mm
MA = M AZYL - M ALP
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MA = 24.82 - 20.78 mm
MA = 4.04 mm
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Thickness of snap ring MASP

MASP = 2,0 mm MALS
Air clearance:
MALS Act = M A - MASP

MALS Act = 4.04 - 2.0 [mm]
MALS Act = 2.04 mm

MALS Des = 1.66 to 1.95 mm
1.4/16 8 HP 55 A 14/11/21
 Snap ring thickness MASP of 2.0 mm
= Inadequate.
New snap ring thickness 2.2 mm
MALS Act = 4.04 - 2.20 [mm]

MALS Act = 1.84 mm
 Snap ring thickness MASP of 2.2 mm

= OK.
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14/11/21 8 HP 55 A 1.4/17
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1.4.6 Brake B air clearance adjustment

end disk 5.1 mm).
 M BEL = 5.1 mm
10173
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package.
Read measurement
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 M BLP = 25.48 mm
10174
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MBLP
25.48
F F = 500 N +/- 5 N
14/11/21 8 HP 55 A 1.4/19
flat surface and set gage to "0".
Place measuring beam on piston B and

find depth for intermediate plate flat
surface.
Piston B must be free of oil and rest

firmly on surface.
Read measurement
 MBZYL = 33.47 mm
10175
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MBZYL
33.47
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Fixed dimension from adjustment

specification transmission housing
package space 61.0 + 0.1 mm.
Average value
 M BBR = 61.05 mm
1.4/20 8 HP 55 A 14/11/21
Air clearance:
MBBR
MBLS Act = M BBR - MBZYL - MBLP
MBLS Act = 61.05 - 33.47 - 25,48 [mm]
MBLS Act = 2.10 mm
MBLS Des = 1.71 to 2.22 mm
MBLS End disk MBEL with 5.1 mm = OK.
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14/11/21 8 HP 55 A 1.4/21
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(Manual transmission only)
1.4.7 Switch adjustment

(locking spring)
Set catch disk to position "N" (neutral)

using a suitable tool or by hand.
13a01
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Align locking spring with fixing device
AA00.600.175.
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Tighten screw on output side first.

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(See section 1.5 for tightening torques)

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13a02
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Then turn it through torsion angle using

tool 5w04.000.583.
Remove centering device.
Cycle selector shaft through all positions

and then remove it again.
13a03
14/11/21 8 HP 55 A 1.4/23
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1.4.8 Bevel gear
(front axle differential)
1.4.8.1 Pinion position
Place measuring unit 5p01.003.652 in

MIN-master 5p89.007.273 and adjust to
fixed dimension as marked on
MIN-master.
Fixed dimension:
56.059 mm
09005 Mit dem MAX-Meister wird gegen
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gemessen.
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Insert auxiliary shaft 5p01.003.656 as far
as possible into converter housing in a
relaxed state.
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13198
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Lock auxiliary shaft.
09007
14/11/21 8 HP 55 A 1.4/25
Insert measuring unit 5p01.003.652 into
converter housing in a relaxed state.
The ball on the measuring sensor must

engage in auxiliary shaft.
Read the measurement:

MBR = 56.021 mm
13199
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1.4.8.2 Pinion shaft beari ng design height
in
Place pinion shaft bearing (with collar
upwards) on tool AA00.591.272.
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09001
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Place tool AA00.591.272 on bearing and

secure with with a wing nut in a positive
connection.
09002
1.4/26 8 HP 55 A 14/11/21
Find dimension from base plate to the
support surface (under the collar) of the
pinion shaft bearing using a height gage.
09003
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Read measurement:
ML = 76.97 mm
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09004
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ML
14/11/21 8 HP 55 A 1.4/27
1.4.8.3 Regulations for the adjusting
washer for the pinion shaft bearing
GR = M BR + M HW
S1
MHW = 117.386 mm (aux. shaft dimension)
S3
GR = 56.021 + 117.386 [mm]
GR = 170.79 mm
R = 95.00 mm
(engraved pinion shaft dimension)
S2
RK = -0.05 mm
(correction value pinion installation)
LK = 0.022 mm
(correction value bearing design height)
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SB = washer cross-section
SB = GR - R - RK - ML - LK
SB = 170.79 - 95 - (-0.05) - 76.97 - 0.022

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SB = 1.465 mm
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Select disk thickness:
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 S1 = 1.475 mm
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1.4/28 8 HP 55 A 14/11/21
1.4.8.4 Crown gear position torsional
clearance
Install bearing shells (35.060/130) and

existing shim S3 (35.140) in differential
cover.
Install bearing shell (35.060/120) and

existing shim S2 (35.130) in converter
housing.
13204
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Insert differential (35.060) into converter
housing.
eL Secure bearing shell in differential cover.
Position differential cover and tighten it

with 4 screws (35.170) crosswise.
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Tightening torque: 27.0 Nm ± 2.7 Nm
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13203
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Place torsion clearance measuring disk

5p01.000.994 on pinion shaft and secure
it.
Screw post on measuring stand

5p01.000.347 into transmission housing
and secure lateral hold-down device with
measuring sensor is perpendicular to
market measurement area of measuring
disk.
13206
14/11/21 8 HP 55 A 1.4/29
Turn pinion shaft one way against pinion /
crown gear toothing.
Set dial to "0".
Carefully turn pinion shaft opposite way as
far as possible.
Find measurement
 MV
Under specification 1084.700.008 edge
clearance M V must be between 0.26 and
0.46 mm with a defined radius (toothing
ratio 11/34).
Read measurement:
MV Ac = 0.44 mm
MV Des = 0.26 to 0.46 mm 13207
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1.4.8.5 Differential prestressing
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Place measuring plate 5p89.000.072 on
differential cover.
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13208
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Screw post on measuring stand

5p01.000.347 with an M8 thread into a
suitable thread in transmission housing.
Secure cross hold-down device with dial

gage sensor is aligned to the center and
perpendicular to measuring plate.
Set dial gage to "0".
13209
1.4/30 8 HP 55 A 14/11/21
Undo 4 screws ½ turn each crosswise
until screws are loose and dial gage does
not change any longer.
Find measurement
 ME
Read measurement ME:

ME Act = 0.24 mm
ME Des = 0.18 to 0.28 mm
Both washer thicknesses (S 2 and S3)

13210 are OK.
e
in
Assumption: if M V Act > 0.46 mm
Reduce size of shim S 2 and enlarge S 3 by

eL same thickness.
Repeat measurement.
ic
rv
Se
ZF
Assumption: if M E Act > 0.28 mm
Reduce size of shim S 3, leave S 2.
Repeat measurement.
14/11/21 8 HP 55 A 1.4/31
1.4.9 Transmission clearance and front
axle output
Find:
Transmission clearance shim S 6

See adjustment specification: 1091.700.043
Front axle output shim S4

Drive wheel shim S 5

e
in
MX5
MY5
MD
MX6
eL
ic
MY6
rv
Se
ZF
S4
MY4 MD M X4
1.4/32 8 HP 55 A 14/11/21
Measurement on intermediate housing:
Place intermediate housing in mounting

device 5p74.000.099.
09040
e
in
Fit drive wheel and front axle shaft with
output gear in intermediate housing.
eL
ic
rv
Se
13230
ZF
Place bearing shells on tapered roller

bearing on front axle shaft and drive wheel.
13231
14/11/21 8 HP 55 A 1.4/33
NOTICE
For adjustment work,
use steel screws.
Place measuring plate of 5p01.000.973

on intermediate housing and secure it
with 11 screws M8x40.
Tightening torque: 27.0 ± 2.7 Nm
13232
e
in
Secure measuring bridge B with 2 dial
gages from tool 5p01.000.973 on setting
master MIN AA00.549.233.
eL
ic
rv
Se
13233
ZF
Set dial gages to fixed dimension (setting

master):
-0,290 mm (transmission clearance)

-0,340 mm (drive wheel)
Unscrew measuring bridge B from setting

master.
13234
1.4/34 8 HP 55 A 14/11/21
Secure measuring bridge B to setting
master MAX 5p89.007.767 and check
measurement and sign.
Desired value:
0.549 mm (transmission clearance)

0,399 mm (drive wheel)
Unscrew measuring bridge B from setting

master MAX.
13236
e
in
Position measuring bridge over drive
wheel and secure it.
eL Turn output gear until the dial gage

indicator no longer changes.
ic
rv
Se
13239
ZF
Read measurements:
MW5 = -0.314 mm
MW6 = 0.047 mm.
Measuring plate thickness
MPL1 = 41.093 mm
This means:
MX5 = M PL1 + M W5
= 41.093 + (-0.314) [mm]
MX5 = 40.779 mm
MX6 = M PL1 + M W6
= 41.093 + (0.047) [mm]
MX6 = 41.140 mm
13240 Unscrew measuring bridge B.
14/11/21 8 HP 55 A 1.4/35
Secure measuring bridge A (one dial
gage) from tool 5p01.000.973 on setting
master MIN AA.549.233.
Set dial gage to fixed dimension (setting

master):
-0.340 mm
Unscrew measuring bridge A from

setting master MIN.
13242
e
in
Secure measuring bridge A on setting
master MAX.
Check measurement and sign.
Desired value:
eL
0.399 mm
ic
Unscrew measuring bridge A from set-
rv
ting master MAX.

Se
13243
ZF
Position measuring bridge A over front

axle shaft and secure it.
Turn output gear until the measurement

no longer changes.
13244
1.4/36 8 HP 55 A 14/11/21
Read measurement:
MW4 = 0.101 mm
Measuring plate thickness
MPL2 = 38.718 mm
This means:
MX4 = M PL2 + M W4
= 38.718 + (0.101) [mm]
MX4 = 38.819 mm
Unscrew measuring bridge A from

measuring plate.
Unscrew measuring plate from

13245 intermediate housing.
e
in
Measurement on transmission housing:
Place measuring device 5p01.003.811 on

eL setting master MIN 5p89.007.918 and set
the fixed dimension:
-41.268 mm
ic
Spring mechanism is to be activated for
rv
this purpose.
Unscrew measuring device.

Se
13247
ZF
Place measuring device on setting master

MAX 5p89.007.919 and check fixed
dimension:
-41.829 mm
Spring mechanism is to be activated for

this purpose.
13252
14/11/21 8 HP 55 A 1.4/37
Place measuring device 5p01.000.972 on
setting master MIN 5p89.007.765 and set
fixed dimension:
Left = -41.592 mm
Right = -39.797 mm
13248
e
in
Place measuring device on setting master
MAX 5p89.007.766 and check fixed
dimension:
Left = -42.357 mm
eL
Right = -39.905 mm
ic
rv
Se
13251
ZF
Secure measuring device 5p01.003.811

to transmission housing and activate
spring mechanism.
Read measurement:
MY6 = 42.805 mm
Unscrew measuring device from trans-

mission housing.
13249
1.4/38 8 HP 55 A 14/11/21
Place measuring device 5p01.000.972
on transmission housing.
Read measurements:
MY4 = (M Y41 + M Y42 + M Y43 ) / 3

MY4 = -39.847 mm
MY5 = (M Y51 + M Y52 + M Y53 ) / 3

MY5 = -41.712 mm
13250
e
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 1.4/39
Determining the washer thickness of transmission clearance S6
(Figure 001, Page 1.4/40)
Package space Transmission clearance Des:

B6 = M Y6 + M D - M X6 0.185 - 0.265 mm
MD = Seal dimension = 0.365 mm
Washer thickness S6
B6 = 42.805 + 0.365 - 41.140 [mm] S6 = B6 - Transmission clearanceAV
= 2.03 mm S6 = 2.03 - 0.225 [mm]

 S6 = 1.80 mm
e
in
Determining the washer thickness of drive wheel S 5
(Figure 001, Pag e 1.4/40)
Drive wheel package space

eL Prestressing Des: -0.06 to 0.01 mm
B5 = M Y5 + M D - M X5 - MK5
ic
MK5 = Correction value = 0.06 mm Washer thickness S5
S5 = B5 - Prestressing Averag e valuet
rv
B5 = 41.712 + 0.365 - 40.779 - 0.06 [mm] S5 = 1.238 - (-0.035) [mm]

= 1.238 mm
 S5 = 1.25 mm
Se
ZF
Determining the washer thickness of front axle output S 4

(Figure 002, Page 1.4/40)
Front axle output package space Prestressing Des : -0.07 to 0.02 mm

B4 = M Y4 + M D - MX4 - M K4
MK4 = Correction value = 0.08 mm Washer thickness S4
S4 = B4 - PrestressingAV
B4 = 39.847 + 0.365 - 38.819 - 0.08 [mm] S4 = 1.313 - (-0.045) [mm]
= 1.313 mm
 S4 = 1.35 mm
8 HP 55 A 14/11/21
1.5 Tightening torques
No. SDM- Designation Wrench size Page Tightening torque

Item No. No.
1. 06.170 Torx screw M6x13 T27H 1.4/23 11.0 Nm
(Locking spring M type) (± 1,1 Nm)
2. 01.100 Sealing screw M10x1 Hexagon socket 3.1/3 8.0 Nm
(Transmission housing PZT) Size = 5 mm (± 0,8 Nm)
3. 01.180 Sealing screw M22x1.5 Hexagon socket 3.1/3 30.0 Nm
(Oil filling) Size = 10 mm (± 3,0 Nm)
4. 24.120 Torx screws M6x20 T27 3.1/4 10.0 Nm
(Guide plate) (± 1,0 Nm)
5. 10.110 Torx screws M6x24 T40 3.3/10 4.0 Nm + 90°
(Intermediate plate) 3.3/11 ± (0.5 Nm + 5°)
e
6. 10.120 Torx screw M6x39 T40 3.3/11 10.0 Nm
(Centering plate) (± 1,0 Nm)
in
(Oil supply) ± (1.0 Nm + 5°)
9. 28.570
(Mechatronic unit)
Torx screws M6x20
(Mechatronic unit)
eLT40
3.5/3
3.5/3
(± 0,8 Nm)
8.0 Nm
(± 0,8 Nm)
ic
10. 28.450 Torx bolts T40 3.5/4 8.0 Nm
28.570 (Oil reservoir) (± 0,8 Nm)
rv
11. 28.580 Torx screw M6x20 T40 3.5/4 8.0 Nm

(Wiring loom) (± 0,8 Nm)
12. 28.650 Torx screw M6x19.5 T40 3.5/5 5.5 Nm
Se
(Guide sleeve) (± 0,55 Nm)

13. 03.030 Torx screws M6x19.5 T40 3.5/6 4.0 Nm + 45°
(Oil pan) ± (0.5 Nm + 5°)
14. 03.010/ Sealing screw M10x1 Hexagon socket 3.5/6 12.0 Nm
ZF
015 (Oil drain screw) Size = 5 mm (± 1,2 Nm)

15. 35.080 Nut M40x1,5 (pinion shaft) Size = 55 mm 3.6/3 Tightening torque:
LH 120.0 Nm ± 1.0 Nm
und 26° ± 1°
Check value:
380 Nm bis 650 Nm
16. 35.080 Nut M40x1,5 (pinion shaft) Size = 55 mm 3.6/3 750 Nm (± 5 %)
Info: Right-hand thread available in
older master parts lists
17. 35.270 Sealing screw M10x1 Hexagon socket 3.6/3 8.0 Nm

(Oil drain screw front axle) Size = 5 mm (± 0,8 Nm)
14/11/21 8 HP 55 A 1.5/1
No. SDM- Designation Wrench size Page Tightening torque
Item No. No.
18. 35.050 Torx screw M6x14 T27 3.6/5 8.0 Nm
(Hold-down device) (± 0,8 Nm)
19. 35.170 Torx screws M8x39 T40 3.6/6 see page 1.3/2
(Differential cover)
20. 35.172 Torx screw, coated T40 3.6/6 see page 1.3/2
(Differential cover)
(Oil filler plug front axle) Size = 8 mm ± (2.7 Nm)
(Converter housing) ± (1.0 Nm + 5°)
23. 35.250 Torx screw M10x27 T40 3.6/9 16.0 Nm
e
(Converter housing) ± (1.6 Nm)
in
24. 97.030 Hexagonal screw Size = 17 mm 3.6/10 15.0 Nm
(Converter retaining bracket) ± (1.5 Nm)
25. 97.020 Hexagonal screw and nut Size = 17 mm 3.6/10 15.0 Nm
26. 35.210
(Converter retaining bracket)
Torx screws M8x22
(Flanged shaft)
eL
T40 3.6/11
± (1.5 Nm)
9.0 Nm + 60°
± (1.0 Nm + 5°)
ic
(Pump) ± (1.0 Nm)
rv

(Side shaft) ± (2.5 Nm)
29. 37.266 Torx screw M8x18 T50 3.7/8 20.0 Nm
Se
(Drive wheel) ± (2.0 Nm)

30. 37.300 Torx screws M8x40 T40 3.7/10 See page 1.3/2
(Intermediate housing)
31. 37.320 Torx screws M10x47 T40 3.7/10 See page 1.3/2
ZF
(Intermediate housing)
32. 37.070/ Sealing screw M12x1.5 Hexagon socket 3.7/10 12.0 Nm
130 (Oil drain screw rear axle) Size = 5 mm ± (1.2 Nm)
(Oil filler plug front axle) Size = 8 mm ± (2.7 Nm)
(Distribution housing) ± (1.0 Nm + 5°)
35. 36.100 Torx screw M8x20 T40 3.7/8 28.0 Nm
(Vibration damper) ± (2.8 Nm)
1.5/2 8 HP 55 A 14/11/21
1.6 Transmission test
The following must be tested:
1. Perfect oil level
Correct oil level, refer to the the specifications of vehicle manufacturer and list of lubricants
TE-ML 11 (Serviceline) and SDM.
2. Oil level too low
There may be the following consequences:

• Engine over-revving or no traction when cornering or moving off
e
• Valve screech caused by air inclusions in the oil
• General malfunctions
in
The results may include the clutches burning out.
3. Oil level too high

eL
Danger of heavy adulteration, foaming, major temperature increases when driving at high
speed. Oil loss through vent, consequences may be burned clutches and gearshift problems.
ic
4. Perfect engine adjustment
rv
Correct idling speed, refer to the vehicle manufacturer's specifications.

Se
5. Traction forwards and backwards
Correct gearshift linkage or cable adjustment, refer to the vehicle manufacturer's

specifications.
ZF
6. Radiator short-circuit or radiator connection on the test bed
Do not overheat the transmission, max. 120°C.
14/11/21 8 HP 55 A 1.6/1
ZF
Se
rv
ic
eL
in
e
1.7 Special tools
ITEM Order No. / Purpose Comment
E1 5p01.000.329 identical
Measuring device multidisk
package (crusher gage) 4 HP 20
---
8 HP
e
in
98008
E2
eL
5p01.000.330
Multidisk package measuring
identical
ic
device (clutch clearance) 4 HP 20
---
(Measuring plate: multidisk 8 HP
rv
package thickness
- short neck > 20 mm
- long neck < 20 mm)
Se
98034
ZF
Multidisk package measuring
device (prestressing) 4 HP 18 Q
---
8 HP
97301
97301
14/11/21 8 HP 55 A 1.7/1
Comment Order No. / Purpose ITEM
E4
identical Manual transmission only:
6 HP 19/A/X 5w04.000.583
--- Torsion measuring device
8 HP assembly locking spring
e
in
98002
identical 5p01.000.972
Measuring device for transmission
eL E5
ic
8 HP 55 A housing bearing depth / bearing
8 HP 55 FL adjustment (2 measurement points)
rv
Se
13261
ZF
identical 5p89.007.765 E6
Setting master for transmission
8 HP 55 A housing bearing depth / bearing
8 HP 55 FL adjustment (2 measurement points)
13262
1.7/2 8 HP 55 A 14/11/21
Setting master MAX transmission
housing bearing depth / bearing 8 HP 55 A
adjustment (2 measurement points) 8 HP 55 FL
e
in
13263
E8
eL
5p01.003.656
Auxiliary shaft
identical
ic
6 HP 28 AF
---
8 HP 55 A
rv
Se
13254
ZF
E9 AA00.591.272 universal
Mount double bearing
13332
14/11/21 8 HP 55 A 1.7/3
identical 5p01.000.994 E 10
Measuring device
8 HP 55 A Torsion clearance
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13333
Measuring stand
eL E 11
ic
8 HP 55 A Axial torsion transmission
8 HP 55 FL clearance
8 HP 90 A
rv
8 HP 90 A 74
Se
13255
ZF
Measuring device
6 HP 28 AF Prestressing differential cover
---
8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
13271
1.7/4 8 HP 55 A 14/11/21
E 13 5p01.000.973 identical
(Measuring bridge A = 1 di al gage)
(Measuring bridge B = 2 dial gages) 8 HP 55 A
Measuring device front axl e 8 HP 55 FL
manual with measuring bar
e
in
13270
E 14
eL
AA00.549.233
Setting master MIN
identical
ic
Measuring device front axl e 8 HP 55 A
manual with measuring bar 8 HP 55 FL
rv
Se
13257
ZF
Setting master MAX
Measuring device front axl e 8 HP 55 A
manual with measuring bar 8 HP 55 FL
13256
14/11/21 8 HP 55 A 1.7/5
Measuring device axi al clearance
8 HP 55 A output
8 HP 55 FL
e
in
13260
Setting master MIN axial
eL E 17
ic
8 HP 55 A clearance output
8 HP 55 FL
rv
Se
13258
ZF
Setting master MAX axial
8 HP 55 A clearance output
8 HP 55 FL
13259
1.7/6 8 HP 55 A 14/11/21
Measuring device pinion position
6 HP 28 AF
5p89.007.273 ---
Setting master MIN 8 HP 55 A
measuring device pinion position 8 HP 55 FL
and differential housing
589.007.277
e
Setting master MAX
measuring device pinion position
in
and differential housing
13331
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 1.7/7
identical AA00.555.684 D1
Support ring for dismantling
8 HP 55 A Snap ring pot 1 (large pot)
8 HP 55 FL
8 HP 70
8 HP 70 X
8 HP 90
8 HP 90 S
8 HP 90 A
e
8 HP 90 74 A
in
13274
identical AA00.558.211
Support ring for dismantling
eL D2
ic
8 HP 55 A Snap ring pot 3 (small pot)
8 HP 55 FL
8 HP 70
rv
8 HP 70 X
8 HP 90
8 HP 90 A
Se
8 HP 90 S
8 HP 90 74 A
13275
ZF
Dismantling device
8 HP Pump from intermediate plate
13340
1.7/8 8 HP 55 A 14/11/21
D4 AA00.653.106 identical
Dismantling device
drive wheel 8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13038
D5
eL
1x56.122.209 / 1x56.122.227
Dismantling device output sealing
universal
ic
sleeve (Kukko standard removal
tools 21/7 and 22/2)
rv
Se
13272
ZF
D6 5x46.003.826 identical
Dismantling
Small needle bearing front axle 8 HP 55 A
shaft 8 HP 90 A
8 HP 90 A 74
(Facom Gleithammer U49P7)
13334
14/11/21 8 HP 55 A 1.7/9
identical 5x46.485.481 D7
Dismantling device for tapered
8 HP 55 A roller bearing front axle shaft
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13266
identical 5x46.003.682
Dismantling device
eL D8
ic
8 HP Nail sleeve from guide wheel
shaft
rv
Se
13338
ZF
identical Dismantling device for tapered D9

roller bearing
8 HP 55 A
8 HP 55 FL 5x46.010.011
8 HP 90 A Basic unit
8 HP 90 A 74 Differential (large/small bearing),
Drive wheel (small bearing),
Front axle shaft
5x46.501.349
Rollex removal tool
Drive wheel (small)
13339
1.7/10 8 HP 55 A 14/11/21
D 10 AA00.549.851 identical
Dismantling device
Connection shaft 6 HP 28 AF
Side shaft with press ---
8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
09117
D 11
eL
AA01.062.070
Di smantling device
identical
ic
Shaft seal pi nion shaft 8 HP 55 A
8 HP 55 FL
rv
Se
13264
ZF
D 12 5x46.003.801 identical
Dismantling device
Pinion / Bearing (combination 6 HP 28 AF
bearing) top bearing section ---
8 HP 55 A
8 HP 55 FL
13265
14/11/21 8 HP 55 A 1.7/11
D 13
Dismantling device
6 HP 28 AF Pinion / Bearing
--- (combination bearing)
8 HP 55 A Bottom tapered roller bearing
8 HP 55 FL
e
in
13273
Sealing sleeve puller
eL D 14
ic
6 HP 26
---
8 HP
rv
Se
10153
ZF

Removal device for
8 HP output flange
Differential
(centrifugal hammer)
14022
1.7/12 8 HP 55 A 14/11/21
D 16 5x46.806.649 identical
Dismantling device tapered roller
bearing differential 8 HP 55 A
(large bearing) 8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
14023
D 17
eL
5x46.002.000
Dismantling device tapered
identical
ic
roller bearing (large bearing) 8 HP 55 A
differential thrust piece, drive 8 HP 55 FL
wheel 8 HP 90 A
rv
8 HP 90 A 74
Se
14028
ZF
D 18 5x46.000.165
Dismantling device tapered roller
bearing front axle shaft thrust
piece
14027
14/11/21 8 HP 55 A 1.7/13
identical 5x46.170.164 D 19
Dismantling device for tapered
8 HP 55 A roller bearing (small bearing)
8 HP 55 FL differential thrust piece, drive
8 HP 90 A wheel, output gear
8 HP 90 A 74
e
in
14029
identical Dismantling device

tapered roller bearing
eL D 20
ic
8 HP 55 A
8 HP 55 FL 5x46.503.491
8 HP 90 A Basic unit output gear,
rv
8 HP 90 A 74 drive wheel (large bearing),

differential (small bearing),
Se
5x46.032.010
Rollex removal tool
drive wheel (large bearing)
output gear
14030
ZF
identical Dismantling device for tapered D 21

roller bearing
8 HP 55 A
8 HP 55 FL 5x46.010.011
8 HP 90 A Basic unit front axle shaft,
8 HP 90 A 74 differential (large/small bearing),
drive wheel (small bearing)
5x46.806.649
Rollex removal tool differential
(large bearing)
14031
1.7/14 8 HP 55 A 14/11/21
D 22 AA00.532.417 identical
Dismantling device
bearing shell drive wheel 8 HP 55 A
8 HP 55 FL
8 HP 90 S
8 HP 90 A
8 HP 90 A 74
e
in
14036
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 1.7/15
identical AA00.686.190 D|M 1

Holding device
8 HP Dismantling / Assembly drive
shaft snap ring gearset 2
e
in
13282
universal AA01.072.185
Mandrel press
eL D|M 2
ic
5x66.000.075
Adapter for support plate
rv
mandrel press
Se
14005
ZF

Dismantling / Assembly device
8 HP 55 A Guide sleeve mechatronic unit
8 HP 55 FL
8 HP 90 S
8 HP 90 A
8 HP 90 A 74
14010
1.7/16 8 HP 55 A 14/11/21
D|M 4 5t66.000.128 identical

Dismantling / Assembly bar
8 HP 90 S
(Index H required to be used for 8 HP 90 A
8 HP) 8 HP 90 A74
e
in
14001
D|M 5
eL
AA00.607.881
Assembly trolley
ic
rv
Se
13362
ZF
D|M 6 AA00.604.766 identical

Rear axle flange 8 HP 55 A
(Distribution housing)
13276
14/11/21 8 HP 55 A 1.7/17
identical 5x46.001.856 D|M 7

Converter lifter (spigot Ø 23)
8 HP 45 X
8 HP 55 A
8 HP 55 FL
8 HP 90 A
e
in
13277
Support dismantling
eL D|M 8
ic
8 HP 55 A vibration damper slot-in shaft
8 HP 55 FL output
8 HP 90 A
rv
8 HP 90 A 74 5p01.000.845
ball bearings flanged shaft and
Se
vibration damper output shaft
13225
ZF
Universal AA00.549.448 D|M 9

Plastic mandrel (short)
10169
1.7/18 8 HP 55 A 14/11/21
D|M 10 5x46.003.687 identical

Mounting device
Converter housing 6 HP 28 AF
---
8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13153
D|M 11
eL
5p74.000.099
Mounting device
only suitable for
8 HP 55 A
ic
intermediate housing
rv
Se
13278
ZF
D|M 12 AA00.561.260 identical
AA00.561.262 6 HP 28 AF
Mounting device ---
Pinion / Bearing / Nut 8 HP 55 A
8 HP 55 FL
13279
14/11/21 8 HP 55 A 1.7/19

Socket wrench pinion
6 HP 28 AF
---
8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13280
Holding tool selector shaft
eL D|M 14
ic
8 HP 55 A (Electric gearshift)
8 HP 55 FL
8 HP 90 A
rv
Se
13143
ZF

Lifting device
8 HP Dismantling / Assembly oil supply
AA00.359.399
Crank
13097
1.7/20 8 HP 55 A 14/11/21

Dismantling / Assembly bar for
disk spring clutch A 8 HP
e
in
13281
D|M 17
eL
5x46.003.957
Lifting device
identical
ic
Di smantling / Assembly tower 8 HP
5w46.000.003
rv
Adapter
Se
10165
ZF

Supporting fixture
Di smantling / Assembly tower 8 HP
10139
14/11/21 8 HP 55 A 1.7/21
universal 5x46.001.376 D|M 19

Pliers snap ring
e
in
10155
Dismantling / Assembly bar
eL D|M 20
ic
8 HP 55 A piston - clutch C
8 HP 55 FL
8 HP 70
rv
8 HP 70 X
8 HP 90
8 HP 90 S
Se
8 HP 90 A
8 HP 90 A 74
10167
ZF

Dismantling / Assembly bar for
8 HP 55 A baffle plate - clutch D
8 HP 55 FL
8 HP 70
8 HP 70 X
8 HP 90
8 HP 90 S
8 HP 90 A
8 HP 90 A 74
14003
1.7/22 8 HP 55 A 14/11/21
M1 5x46.003.843 identical
Auxiliary tool for output gear and
front axle shaft 6 HP 28 AF
---
8 HP 55 A
8 HP 90 A
8 HP 90 A 74
e
in
14006
M2
eL
AA00.381.834
Assembly and centering device
identical
ic
rectangular rings drive shaft 8 HP
rv
Se
14013
ZF
M3 AA00.549.949 identical
Centering device rectangular
rings drive shaft 8 HP
14020
14/11/21 8 HP 55 A 1.7/23
identical AA00.621.827 M4
Assembly device for small
8 HP 55 A tapered roller bearing on drive
8 HP 55 FL wheel
8 HP 90 S
8 HP 90 A
8 HP 90 A 74
e
in
13316
Assembly device for large tapered
eL M5
ic
8 HP 55 A roller bearing on drive wheel
8 HP 55 FL
8 HP 90 A
rv
8 HP 90 A 74
Se
13318
ZF
identical AA00.578.569 M6
Press-in device bearing / output
8 HP 55 A flange and WDR in distribution
8 HP 90 A housing
8 HP 90 A 74
13365
1.7/24 8 HP 55 A 14/11/21
M7 AA00.574.045 identical
Drive-in tool sealing sleeve
Transmission housing, outside 8 HP 55 A
8 HP 55 FL
8 HP 90 S
8 HP 90 A
8 HP 90 A 74
e
in
14038
M8
eL
AA00.554.817
Drive-in tool sealing sleeve
identical
ic
Transmission housing, inside 8 HP 55 A
8 HP 55 FL
8 HP 90 S
rv
8 HP 90 A
8 HP 90 A 74
Se
13296
ZF
M9 5x46.002.561 identical
Drive-in mandrel shaft seal
Selector shaft 6 HP 26
----
8 HP
10149
14/11/21 8 HP 55 A 1.7/25
M 10
identical Manual transmission only:
8 HP 45 X AA00.600.175
8 HP 55 A Fixing device locking spring
8 HP 90 S
8 HP 90 A
e
in
02026
Drive-in tool clamping sleeve
eL M 11
ic
5 HP
6 HP
8 HP
rv
Se
13285
ZF
identical AA00.637.175 M 12
Assembly device round wire ring
8 HP cylinders C + E
10158
1.7/26 8 HP 55 A 14/11/21
M 13 AA00.548.688 identical
Assembly pliers snap ring
gearset 3 / pot 2 / pot 1 8 HP
e
in
13127
M 14
eL
5x46.003.918
Assembly device snap ring
identical
ic
gearset 2 on drive shaft 8 HP 55 A
8 HP 55 FL
8 HP 70
rv
Se
10157
ZF
M 15 5x46.003.913 identical
Press-in tool for pump into
intermediate plate 8 HP
10162
14/11/21 8 HP 55 A 1.7/27
M 16
Clamping device screw
8 HP connection pump + intermediate
plate
e
in
14007
Drive-in mandrel cylindrical pin
eL M 17
ic
8 HP in transmission housing
(intermediate plate)
rv
Se
14004
ZF
Plate for pressing off the clutches
8 HP
13286
1.7/28 8 HP 55 A 14/11/21
M 19 Manual transmission only: identical
AA00.603.510 8 HP 45 X
Alignment device selected slide 8 HP 55 A
and position sensor 8 HP 90 S
8 HP 90 A
e
in
13287
M 20
eL
5x46.001.521
Securing pins oil pan
identical
ic
8 HP
rv
Se
13288
ZF
Press-on device
tapered roller bearing on 8 HP 55 A
differential (large bearing) 8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
13289
14/11/21 8 HP 55 A 1.7/29
identical 5x46.002.218 M 22
Press-on device
8 HP 55 A tapered roller bearing on
8 HP 55 FL differential (small bearing)
8 HP 90 A
8 HP 90 A 74
e
in
14035
Press-in device
eL M 23
ic
8 HP 55 A shaft sealing ring pinion shaft
8 HP 55 FL
rv
Se
14037
ZF
Assembly mandrel shaft sealing
8 HP 55 A ring differential flanged shaft in
8 HP 55 FL converter housing
8 HP 90 A
8 HP 90 A 74
13291
1.7/30 8 HP 55 A 14/11/21
Press-in tool for seal hold-down
device 8 HP 55 A
8 HP 90 A
8 HP 90 A 74
8 HP 55 A
5x46.004.033 8 HP 55 FL
Assembly sleeve 8 HP 90 A
e
seal hold-down device on drive 8 HP 90 A 74
wheel
in
13324
M 26
eL
AA00.578.639
Press-in device
identical
ic
shaft sealing ring in differential 6 HP 28 AF
cover ---
8 HP 55 A
rv
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
Se
13293
ZF
Assembly device for half-moon
ring, flanged shaft 8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
13294
14/11/21 8 HP 55 A 1.7/31
5x46.003.018 M 28
Drive-in mandrel for vent pipe
e
in
13295
Assembly mandrel shaft
eL M 29
ic
8 HP sealing ring and needle bearing in
centering plate
rv
Se
10163
ZF
Press-in device bearing shells in
8 HP 55 A front axle housing
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
13335
1.7/32 8 HP 55 A 14/11/21
M 31 AA00.625.669 identical
Drive-in device bearing shell,
drive wheel in transmission 8 HP 55 A
housing 8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
e
in
13337
M 32
eL
5x46.003.834
Drive-in device bearing shell,
identical
ic
front axle in transmission housing 8 HP 55 A
8 HP 55 FL
8 HP 90 A
rv
8 HP 90 A 74
Se
13313
ZF
Press-on device bearing and disk
on side shaft 6 HP 28 AF
---
8 HP 55 A
8 HP 55 FL
8 HP 90 A
8 HP 90 A 74
13341
14/11/21 8 HP 55 A 1.7/33
Press-in device needle sleeve
6 HP 28 AF 1 + 2 and tapered roller bearing
--- on output gear
8 HP 55 A
8 HP 55
e
in
13336
Assembly device needle sleeve on
eL M 35
ic
6 HP 28 AF front axle shaft
---
8 HP 55 A
rv
8 HP 90 A
8 HP 90 A 74
Se
13364
ZF
counter support transmission
8 HP 55 A housing
8 HP 55 FL
14048
1.7/34 8 HP 55 A 14/11/21
1.8 Oil flow diagram
1.8.1 DIN schematic E26/4
e
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 1.8/1
e
in
eL
ic
rv
Se
ZF
1.8/2 8 HP 55 A 14/11/21
e
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 1.8/3
e
in
eL
ic
rv
Se
ZF
1.8/4 8 HP 55 A 14/11/21
2. Dismantling
2.1 Preparations
2.1.1 Drain transmission oil
Attach transmission in assembly bar

5t66.000.128 to assembly trolley
AA00.607.881.
The oil pan must be facing downwards.
13021
e
The transmission has 3 oil systems .
in
Drain residual oil:
1. Unscrew oil drain and oil filler

eL screws from oil pan and transmission
housing.
2. Unscrew front differential oil drain

ic
and oil filler plugs from converter
housing and differential cover.
rv
3. Unscrew front differential oil drain

and oil filler plugs from converter
housing and differential cover.
Se
ZF
14/11/21 8 HP 55 A 2.1/1
ZF
Se
rv
ic
eL
in
e
2.2 Transmission clearance and
front axle output
2.2.1 Remove and dismantle

distribution housing
Turn transmission with converter side at

bottom.
13023
e
in
Remove 6 screws from distribution
housing.
eL Remove distribution housing.
Remove torsen differential upwards.

ic
rv
Se
13022
ZF
Insert distribution housing into device

5p01.000.845.
Position support AA00.356.002 between

distribution housing and vibration
damper.
Pull O-ring off distribution housing.
13343
14/11/21 8 HP 55 A 2.2/1
Remove small snap ring from slot-in
shaft.
Press out slot-in shaft using mandrel

press.
Take distribution housing out of device.
Remove shaft sealing ring with suitable

tools.
13028
e
Transmission with bending vibration
damper
in
Undo 3 screws on vibration damper and
lift up vibration damper.
eL
ic
rv
Se
13a09
Transmission with spray ring

ZF
Remove spray ring with mandrel press.
14039
2.2/2 8 HP 55 A 14/11/21
Remove large snap ring for ball bearing
from distribution housing.
Press out ball bearing using suitable tools

using mandrel press.
13359
e
2.2.2 Remove intermediate housing
and dismantle front axle output
in
Remove 15 screws from intermediate
housing.
eL
ic
rv
Se
13068
ZF
Drive both clamping sleeves approx. 10 mm

towards transmission housing with a drive-
in mandrel.
Remove intermediate housing.
Remove seal and magnet.
13069
14/11/21 8 HP 55 A 2.2/3
NOTICE
If the needle bearing is damaged the
complete oil pump must be replaced.
Remove 4 screws from oil pump.
Remove oil pump and pump annulus

from intermediate housing.
13029
e
in
Remove output gear.
eL
ic
rv
Se
13030
ZF
Undo screw in drive wheel and remove it.
13031
2.2/4 8 HP 55 A 14/11/21
Release drive wheel using tool
AA00.653.106.
Remove tool and drive wheel.
13032
e
in
Remove transmission clearance shim
with magnet.
eL
ic
rv
Se
13142
ZF
Remove front axle shaft.
13034
14/11/21 8 HP 55 A 2.2/5
Remove 2 screws from pinion shaft
retaining plate.
Remove pinion with side shaft.
08060
e
in
NOTICE
The oil distributor will be destroyed
when it is removed.
Pull out oil distributor on rear of

eL
transmission housing with pliers.
ic
rv
Se
13036
ZF
Place tool AA00.532.417 on drive shaft.
Pull off bearing shell using tool.
Remove shim.
14033
2.2/6 8 HP 55 A 14/11/21
Place plastic panel on transmission
housing for protection.
Pull out FA shaft bearing shell with tool

1X56.122.209/1X56.122.227.
14040
e
2.2.3 Dismantle front axle shaft
in
Remove the needle bearing with thrust
washer from front axle shaft.
eL
ic
rv
Se
13040
ZF
Pull small needle sleeve out of front axle

shaft using a suitable tool, for example
5x46.003.826 (Facom U.49P3 10-13 mm).
08063
14/11/21 8 HP 55 A 2.2/7
Place washer 5x46.000.165 on borehole
in front axle shaft.
14024
e
in
Position a suitable tool, for example
5x46.485.481 (Kukko puller) over
washer on front axle shaft.
eL
ic
rv
Se
14025
ZF
Pull tapered roller bearing off front axle

shaft with tool.
14026
2.2/8 8 HP 55 A 14/11/21
2.2.4 Dismantle output gear
Using a suitable tool lever out snap ring

in output gear at notch and remove it.
13041
e
in
Pull large needle sleeve out of output
gear using a suitable tool (for example
Facom U.49P3 38-50 mm).
eL
ic
rv
Se
08064
ZF
Pull small needle sleeve out of output

gear using a suitable tool, for example
5x46.003.682 (Facom U.49P3 30-38 mm).
08065
14/11/21 8 HP 55 A 2.2/9
Cover borehole in output gear with a
washer 5x46.002.000.
Pull tapered roller bearing off output gear

using a suitable tool, for example basic
unit 5x46.010.011 and Rollex puller
5x46.501.349.
08066
e
2.2.5 Dismantle drive wheel
in
Lever disk spring out of drive wheel
using a suitable tool.
eL
ic
rv
Se
13072
ZF
Cover borehole in drive wheel with a

washer 5x46.170.164.
Pull small tapered roller bearing off drive

wheel using a suitable tool, for example
basic unit 5x46.010.011 and Rollex
puller 5x46.501.349.
Remove shaft sealing ring.
Turn drive wheel over.
13042
2.2/10 8 HP 55 A 14/11/21
Cover borehole in drive wheel with a
washer 5x46.002.000.
Pull large tapered roller bearing off drive

wheel using a suitable tool, for example
basic unit 5x46.503.491 and Rollex
puller 5x46.032.010.
08068
e
2.2.6 Dismantle side shaft
in
Remove snap ring from side shaft ball
bearing.
eL Insert side shaft into dismantling device

AA00.549.851.
Press side shaft out of the sleeve using
the mandrel.
ic
rv
Se
08068
ZF
Press out bearing and retaining plate

using a suitable tool using mandrel press.
08069
14/11/21 8 HP 55 A 2.2/11
ZF
Se
rv
ic
eL
in
e
2.3 Remove flanged shaft, front
axle differential and converter
2.3.1 Remove flanged shaft and front

axle differential
Lever out flange using tool

AA00.612.091 or a suitable tool.
Lever ocking ring out of flange using a

screwdriver.
14015
e
in
Remove 11 screws from differential
cover.
eL Carefully release differential cover from

converter housing with a plastic mallet
and remove it.
ic
Remove crown gear.
rv
Se
14016
ZF
Place thrust piece 5x46.002.000 on

crown gear borehole.
Position tool 5x46.806.649 on crown

gear and pull off large tapered roller
bearing.
Turn over crown gear.
Place thrust piece 5x46.170.164 on

crown gear borehole.
Position tool 5x46.503.491 on crown

gear and pull off small tapered roller
14019 bearing.
14/11/21 8 HP 55 A 2.3/1
Pull O-ring off differential cover.
14017
e
in
Remove bearing shell and shim from
differential cover.
Drive shaft sealing ring out of differential

cover using a suitable tool.
eL
ic
rv
Se
13053
ZF
Remove bearing shell and shim from

converter housing.
14041
2.3/2 8 HP 55 A 14/11/21
Remove 3 screws from flanged shaft
hold-down device.
Remove the flanged shaft and hold-down

device from transmission housing.
08081
e
2.3.2 Dismantle flanged shaft
in
Remove springs and tappets from flanged
shaft using a suitable tool.
eL
ic
rv
Se
14008
ZF
Remove locking ring from flanged shaft.
13045
14/11/21 8 HP 55 A 2.3/3
Press bearing and hold-down device with
support AA00.356.002 off flanged shaft
13298
e
2.3.3 Remove converter
in
Unscrew hexagon screw with nut
(M12x70) and hexagon screw (M12x16)
from converter retaining bar.
Remove converter retaining bar.

eL
ic
rv
Se
13046
! WARNING
ZF
RISK OF ACCIDENT! The lifting and

moving of he avy parts without lifting
equipment can lead to damage to health
and sever e injuries.
ð Use a crane or similar lifting equipment.
Remove converter with converter lifter

5x46.001.856.
Pull O-ring off drive shaft.
14051
2.3/4 8 HP 55 A 14/11/21
2.3.4 Remove converter housing
Turn transmission with converter side at

the top.
Undo 1 screw outside and 14 screws

inside converter housing.
13056
e
in
Release converter housing from
transmission housing using a plastic
mallet and remove it.
eL Remove seal.
ic
rv
Se
13057
ZF
Pull protective tube with sealing ring out

of transmission housing.
Pull sealing ring off protective tube.
13070
14/11/21 8 HP 55 A 2.3/5
Lever sealing ring off transmission
housing using a suitable tool.
13058
e
2.3.5 Dismantle converter housing
in
Fit and secure holding device
5x46.003.687 on assembly trolley or
workbench.
eL
ic
rv
Se
13117
ZF
Position converter housing in both

adjusting pins.
13118
2.3/6 8 HP 55 A 14/11/21
Position two clamping elements and
clamp converter housing.
13119
e
in
Remove drive shaft sealing ring.
eL
ic
rv
Se
13116
ZF
Drive out flanged shaft sealing ring in

converter housing using tool.
14042
14/11/21 8 HP 55 A 2.3/7
Undo retaining plate screw from
converter housing.
Remove retaining plate and magnet.
13059
e
in
Push two bolts on tool AA01.062.070
through two marks on shaft sealing ring
(side shaft) and turn them through 90°.
Lock both bolts with puller and pull out

shaft sealing ring by turning spindle.
eL
ic
rv
Se
13063
2.3.6 Remove pinion shaft
ZF
Remove locking ring from pinion shaft.
13073
2.3/8 8 HP 55 A 14/11/21
Turn device with converter housing
through 90°.
! CAUTION
Danger of burns
ð Wear safety gloves
Heat converter housing on bearing seat

of pinion shaft with a hot air blower.
13120
e
in
Pull out pinion shaft and put it down
carefully.
eL Allow converter housing to cool.

ic
rv
Se
13122
2.3.7 Dismantle pinion shaft

ZF
Pinion shaft with left-hand thread
Insert pinion shaft into mounting device

AA00.561.260 and stop lock nut turning
counter-clockwise using a hold-down
device.
13123
14/11/21 8 HP 55 A 2.3/9
Release pinion shaft with socket wrench
AA00.561.169 turning it counter-
clockwise - reducer section, toggle bar or
ratchet and extension tube (> 1,000 mm
length) and unscrew it from the lock nut.
Remove hold-down device, lock nut and

pinion shaft.
13124
e
Pinion shaft with right-hand thread
in
Insert pinion shaft into dismantling
device AA00.561.260 and stop lock nut
turning clockwise using a hold-down
device. eL
ic
rv
Se
09138
ZF
Release pinion shaft turning it clockwise

with socket wrench AA00.561.169 -
reducer section, toggle bar or ratchet and
extension tube (> 1,000 mm length) and
unscrew it from lock nut.
Remove hold-down device, lock nut and

pinion shaft.
13140
2.3/10 8 HP 55 A 14/11/21
device 5x46.003.801.
Press out slot-in shaft using the mandrel

press.
Remove pinion shaft and bearing from

device.
08098
e
in
device 5x46.003.801.
eL Press the internal bearing ring off

pinion shaft using dismantling device
5x46.802.048 and mandrel press.
ic
rv
Se
01051
ZF
14/11/21 8 HP 55 A 2.3/11
ZF
Se
rv
ic
eL
in
e
2.4 Remove oil pan, mechatronic
unit and parking lock
2.4.1 Remove oil pan and oil filter
Unscrew 12 aluminum cap screws which

secure oil pan.
Lever off oil pan.
Remove seal.
13075
e
in
Carefully lever out and remove oil filter.
eL
ic
rv
Se
13077
2.4.2 Remove mechatronic unit

ZF
Undo aluminum screw in guide sleeve.
14010
14/11/21 8 HP 55 A 2.4/1
Place tool AA00.615.807 on guide sleeve.
Turn guide sleeve counter-clockwise with

tool as far as possible and pull it out.
14009
e
Transmission with oil reservoir
in
Disconnect cable plug from oil reservoir
using long nose pliers.
eL
ic
rv
Se
11004
ZF
Remove 3 screws from oil reservoir.
11005
2.4/2 8 HP 55 A 14/11/21
Carefully remove oil reservoir.
11006
e
in
NOTICE
You could damage the pressure nozzle
eL of the oil reservoir!
Pull O-ring off oil reservoir.

ic
rv
Se
11007
ZF
Undo 4 screws (thick screw head) from

mechatronic unit and speed sensor on
output side.
3 screws on a transmission with oil

reservoir.
13080
14/11/21 8 HP 55 A 2.4/3
Remove speed sensor and insert into the
notch in module.
13081
e
in
Remove screw from cable loom.
eL
ic
rv
Se
13082
Transmission with electric gearshift

ZF
Push tool AA00.564.638 over selector

shaft and locked it on transmission
housing.
13144
2.4/4 8 HP 55 A 14/11/21
Undo 14 long screws (thick screw head)
from mechatronic unit.
13083
e
in
NOTICE
The mechatronic unit may jam.
eL Carefully release mechatronic unit by
levering it.
ic
rv
Se
13084
ZF
Remove pressure tube from mechatronic

unit or transmission housing.
Pull out sealing sleeve by hand or using

tool 5x46.001.210.
13085
14/11/21 8 HP 55 A 2.4/5
2.4.3 Remove parking lock
Remove 3 screws from guide plate.
Remove guide plate.
13086
e
in
Press out parking lock bolt with a
screwdriver.
Remove pawl and spring.
Wipe O-ring on parking lock bolt.

eL
ic
rv
Se
13088
Transmission with manual gearshift

ZF
Drive out selector shaft clamping pin

using a punch mandrel.
Remove selector shaft and catch disk.
13089
2.4/6 8 HP 55 A 14/11/21
Detach connection rod from catch disk.
13091
e
Transmission with electric gearshift
in
Remove selector shaft holding tool.
Drive out selector shaft clamping pin

eL using a punch mandrel.
Remove clamping pin.

ic
rv
Se
13145
ZF
Remove selector shaft from parking disc.
Remove parking lock with leg spring.
Detach connection rod from parking disc.
13146
14/11/21 8 HP 55 A 2.4/7
Use suitable tools to remove sealing ring
for selector shaft.
13092
e
in
Unscrew PZT sealing screw from
transmission housing.
eL
ic
rv
Se
13093
ZF
2.4/8 8 HP 55 A 14/11/21
2.5 Remove and dismantle oil
supply
2.5.1 Remove oil supply
Remove 14 screws from oil supply.
13095
e
in
Position lifting device AA00.549.802 and
lock it with slide.
eL Turn crank AA00.359.399 clockwise

until oil supply is released.
Lift out oil supply and put it down.

ic
Remove lifting device.
rv
Se
13096
2.5.2 Dismantle oil supply

ZF
! CAUTION
Cylinder may jump out under pressure.
Release cylinder B from intermediate

plate with compressed air and remove it.
Remove piston B.
10046
14/11/21 8 HP 55 A 2.5/1
Pull profile and lip sealing ring off
piston.
13099
e
in
Remove axial needle bearing from
multidisk carrier.
eL
ic
rv
Se
13102
ZF
Pull O-ring off intermediate plate.
13103
2.5/2 8 HP 55 A 14/11/21
Lever snap ring out of brake A.
Remove multidisk carrier A, sun shaft 1

and multidisk package.

intermediate plate.
Remove angle disc from multidisk
carrier.
13104
e
in
Remove coil spring and external disk.
Push down piston A using dismantling

eL bar 5x46.001.502 under mandrel press.
Remove retaining rings and disk spring.

ic
rv
Se
10048
ZF
Remove piston A by turning and pulling

it.
Pull off 2 lip sealing rings.
10049
14/11/21 8 HP 55 A 2.5/3
Undo 5 screws in cylinder A and 1 screw
outside cylinder.
13106
e
in
Turn unit over.
Remove screw from centering plate.
Lift off centering plate.

eL
ic
rv
Se
13126
ZF
NOTICE
If the axial needle bearing is
damaged on the guide wheel shaft or
intermediate plate, the complete unit
must be replaced.
Carefully pull out pump with chain

drive using tool AA00.566.429 and
remove it.
Remove 2 O-rings and a sealing element

from underside of the pump.
13367
2.5/4 8 HP 55 A 14/11/21
2.6 Remove and dismantle tower
Place tower lifter 5x46 003 957 on the

input shaft and secure with damber.
Extract tower with crane or lifting aid.
13098
e
in
Place tower in device 5x46 004 264.
Extract power lifter.

eL Extract multidisk carrier B incl. internal
ring gear (a component) with brake B.
ic
rv
Se
10021
ZF
Remove washer from internal ri ng gear.
Extract axial needle bearing with fixing

plate from planet carrier.
14045
14/11/21 8 HP 55 A 2.6/1
NOTICE
Hold pot 1 to prevent it from falling.
Place support ring AA00.555.684

(protection from levering tool) on pot 1.
Lever out snap ring with a screwdriver

opposite the snap ring opening and
remove it.
10023
e
in
Remove gearset 1.
Remove sun gears 1 and 2.
Remove drive shaft with gearset 2.

eL
ic
rv
Se
10199
ZF
Place drive side of drive shaft in

mounting device.
Pull 7 rectangular rings off drive shaft.
Remove axial needle bearing and angle

washer from annulus 2.

gearset 2.
10025
2.6/2 8 HP 55 A 14/11/21
Lever out thrust washer fro planetary
support 2.
Remove snap ring with suitable tools.
Remove gearset upwards.
10026
e
in
NOTICE
Locking spigots may break, so
eL screwdrivers should be placed on
several points.
Lever oil collection tray out of planetary

ic
support 2 with a screwdriver.
rv
Lever oil collection tray out of planetary

support 1 with a screwdriver.
Se
10027
ZF
Remove annulus 2 with sun gear 3 from

post 2.
Remove angle washer from sun gear 3.
Release snap ring.
Put down annulus and sun gear.
10028
14/11/21 8 HP 55 A 2.6/3
Pull pot 2 upwards out of pot 1.
10200
e
in
Remove coupling D from pot 1.
eL
ic
rv
Se
13109
ZF
Place pot 2 in supporting fixture

5x46.004.264.
Place support ring AA00.558.211 on pot 2.
Lever out snap ring with a screwdriver

and remove it.
10201
2.6/4 8 HP 55 A 14/11/21
Extract gear set 3.
Extract axial needle bearing from gear set.
10030
e
in
Detach snap ring 1 and extract ring
gear 3.
eL Detach snap ring 2 (support for internal

ring gear).
ic
rv
Se
10031
ZF
Extract clutch E.
Extract axial needle bearing on the upper

side of clutch E.
10032
14/11/21 8 HP 55 A 2.6/5
Remove clutch C.
Remove a combination bearing from top

and bottom of clutch C.
10033
e
in
Remove sun shaft with sun gear 4.
eL
ic
rv
Se
10202
ZF
Remove snap ring with snap ring pliers

5x46.001.376.
Remove annulus from gearset 4 from pot.
10041
2.6/6 8 HP 55 A 14/11/21
2.7 Remove clutches
2.7.1 Remove clutch E
Press dismantling bar 5x46.000.167 on

baffle plate and remove round wire ring.
Remove piston with baffle plate.
Remove baffle plate from piston.
Wipe lip sealing ring from baffle plate.
10044
e
in
Remove disk spring and multidisk
package.
eL Remove multidisk carrier.
Wipe 2 O-rings.
ic
rv
Se
10045
2.7.2 Remove clutch C

ZF
Press dismantling bar 5x46.000.167 on

baffle plate and remove snap ring.
Remove piston with baffle plate.
Remove baffle plate from piston.
Wipe lip sealing ring from baffle plate.
10042
14/11/21 8 HP 55 A 2.7/1
Remove disk spring and multidisk
package.
Remove multidisk carrier.
Pull hub out of multidisk carrier.
Wipe 4 O-rings (2 inside, 2 outside) from

hub.
10043
e
2.7.3 Remove clutch D
in
Remove snap ring.
Remove multidisk package.

eL
ic
rv
Se
13110
ZF
Position tool AA00.349.340 with both

pins in baffle plate and secure it.
13a06
2.7/2 8 HP 55 A 14/11/21
Place clutch D with tool in mandrel
press.
Turn tool clockwise applying slight

pressure from mandrel press until detents
have engaged.
Remove baffle plate and disk spring.
Remove the O-ring from the baffle plate.
13a08
e
in
Pull out piston D by hand.
Wipe O-ring from piston D.

eL
ic
rv
Se
13113
ZF
Pull 2 rectangular rings off output shaft.
13115
14/11/21 8 HP 55 A 2.7/3
Protect transmission housing sealing
surface with a suitable support.
Pull off external sealing sleeves using

tool 1x56.122.209/1x56.122.227.
Drive out internal sealing sleeves with

suitable tool.
14034
e
in
eL
ic
rv
Se
ZF
2.7/4 8 HP 55 A 14/11/21
3. Assembly
3.1 Preparations
01.050
01.010
01.180
01.040
01.060
24.030
24.010
24.040
01.100 24.060
e
01.040
24.110
in
24.080
06.144 24.120
06.060
06.010
06.170 eL 06.090
06.050
06.010
ks
pe
rr e
/ Pa
r ki
ng
b ra
ke
06.030 ar
06.110 -P
ic
24
06.050
06 06 06.060
-M - E- S
rv
-Sc c ha
h alt lt u
un ng
g /E
/M le c
an t r ic
ual sh
s hif if t
t s ys
sys te
t em m
Se
ZF
Attach transmission housing (01.010)

with retaining bracket 5t66.000.128 to
assembly trolley AA00.607.881.
13158
14/11/21 8 HP 55 A 3.1/1
New housing
Place outside sealing sleeve (01.050)

onto tool AA00.574.045 and drive it into
14046
e
in
Rotate transmission housing by 180°.
Place inside sealing sleeve (01.050) onto

tool AA00.554.817 and drive it into
eL
ic
rv
Se
14047
New housing
ZF
Drive two bushes (01.040) into

transmission housing on converter
housing sealing surface.
13148
3.1/2 8 HP 55 A 14/11/21
NOTICE
Depending on the oil filling method,
turn in the screw hand-tight or to
tightening torque.
Screw new sealing screw PZT (01.100)

into transmission housing.
13149
e
in
Screw new oil filler sealing screw
(01.180) into transmission housing.
eL (See section 1.5 for tightening torques)

ic
rv
Se
13156
3.1.1 Install parking lock and

gearshift
ZF
Place new gearshift lever shaft sealing

ring (06.010) in tool 5x46.002.561
and drive it into transmission housing.
Manual gearshift and new housing
13162
14/11/21 8 HP 55 A 3.1/3
Fit new O-ring (24.030) on parking lock
bolt (24.010).
13151
e
in
Fit pawl (24.040) with leg spring
(24.060) in transmission housing.
eL
ic
Secure pawl by pressing in parking lock
rv
bolt on output side.

Se
13297
Manual gearshift and new housing

ZF
Refer to section 1.4.7. Adjustment work
Secure locking spring (06.144) with 2

torx screws (06.170) with locking spring
can be turned easily.
13a05
3.1/4 8 HP 55 A 14/11/21
Press down pawl and place guide plate
(24.110) on it.
Secure it with 3 new hexalobular screws

(24.120).
13157
e
in
Attach connecting rod (24.080) to
parking and catch disk (06.050) and
turn it.
eL
ic
rv
Se
13150
ZF
1. Press down the pawl.
1. 2. Fit connecting rod between guide

plate and pawl.
2.
13160
14/11/21 8 HP 55 A 3.1/5
Manual gearshift
Slide gearshift lever with selector shaft

(06.110) through catch disk.
Position selector shaft with the catch disk

borehole and selector shaft borehole are
in line.
13161
e
Electric gearshift
in
Slide selector shaft (06.030) through
parking washer and leg spring
(06.090).
Position selector shaft with parking disk

borehole and selector shaft borehole are
eL
in line.
ic
rv
Se
13146
ZF
Drive in new clamping sleeve (06.060)

in the position shown using tool
5x46.001.368.
13159
3.1/6 8 HP 55 A 14/11/21
Manual gearshift
Fit catch disk in P position on locking

spring.
13160
e
Electric gearshift
in
Slide tool AA00.564.638 over selector
shaft and lock on the transmission
housing.
eL
ic
rv
Se
14049
ZF
14/11/21 8 HP 55 A 3.1/7
ZF
Se
rv
ic
eL
in
e
3.2 Assemble clutches and oil supply
3.2 Kupplungen montieren
42.270 73.030
42.010 73.070
73.050
73.100
.4 73.080
no
et
rs 73.120
gea
y
t ar
ne 73.140
P la
4/
tz
d sa 73.160 75.220
e nra
n et 75.200
- Pla 75.180
42 73.170
75.160
73.180
75.120
75.060
75.080
e
75.100
D 71.120
tc h
/ Clu 75.110 71.110
gD 71.100
lu n
in
upp 75.130
K
7 3- 75.050
71.070
71.030
75.020
75.010
lut
ch
C
eL
71.060
71.050
71.040
C /C 71.140
ic
ng 71.090
p lu
Kup 71.080
-
75 71.010/020
rv
71.010/010
E
tc h
Clu
g E/
lun
Se
pp
- Ku
71
3.2.1 Clutch D
ZF
The sealing element in the output shaft

(cylinder D) is riveted and cannot be
replaced.
If it is damaged the complete com-
ponent (output shaft with gearset and
cylinder D) must be replaced.
Fit 2 new rectangular rings (42.270) on

output shaft (42.010).
13115
14/11/21 8 HP 55 A 3.2/1
Place output shaft in supporting fixture
5x46.004.264.
10054
e
in
Fit new O-ring (73.050) on piston D
(73.030).
Press piston D into cylinder D.
Insert disk spring (73.070).

eL
ic
rv
Se
10055
ZF
Fit new O-ring (73.100) on baffle plate

(73.080).
Position recesses in the baffle plate over

appropriate spigot.
Press down baffle plate using tool

AA00.349.340 using mandrel press and
turn it counter-clockwise until small
spigot is positioned between securing
lugs.
13a08
3.2/2 8 HP 55 A 14/11/21
NOTICE
Insert multidisk package.

Start with a coil spring (73.120), then
insert external disks (73.140) and lining
disks (73.160) alternately.
Finally fit an end disk (73.170).
Secure end disk with a snap ring

(73.180).
10058
e
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 3.2/3
3.2.2 Clutch C
Fit 4 new O-rings (2 internal 75.020,

2 external 75.130) on hub (75.010).
10059
e
in
Fit hub into cylinder C (75.050).
Fit disk spring (75.120) into cylinder.

eL
ic
rv
Se
10060
ZF
NOTICE

insert lining disks (75.100) and internal
Finally fit a coil spring (75.060).
10061
3.2/4 8 HP 55 A 14/11/21
NOTICE
The sealing element on piston C is
vulcanized and cannot be replaced
separately.
Press fit piston C (75.160) onto c ylinder C.
10062
e
in
Press support washer (75.180) with a new
lip sealing ring (75.200) into piston C.
eL
ic
rv
Se
10063
ZF
Press down support washer with

assembly bar 5x46.000.167 using
mandrel press and secure it with a new
snap ring (75.220).
Place assembly device AA00.637.175

over hub of cylinder C and fit snap ring
with thrust piece.
10064
14/11/21 8 HP 55 A 3.2/5
3.2.3 Clutch E
Fit 2 new O-rings (71.080, 71.090) on

cylinder E (71.010).
Fit disk spring (71.070) into cylinder E.
10065
e
in
NOTICE

eL
insert lining disks (71.050) and internal
ic
rv
Se
10066
ZF
NOTICE
The sealing element on piston E is
vulcanized and cannot be replaced
separately.
Press fit piston E (71.100) onto cylinder E.
10067
3.2/6 8 HP 55 A 14/11/21
Press support washer (71.110) with a new
lip sealing ring (71.120) into piston E.
10068
e
in
Press down support washer with
assembly bar 5x46.000.167 using
mandrel press and secure it with a new
eL snap ring (71.140).
Place assembly device AA00.637.175

over hub of cylinder E and fit round wire
ic
ring with thrust piece.
rv
Se
10069
ZF
14/11/21 8 HP 55 A 3.2/7
ZF
Se
rv
ic
eL
in
e
3.3 Assemble tower and oil supply
10.210
10 .010/ 06 0
10.010/050
10 .01 0 32 .05 0
32 .060
32 .02 0
10 .10 0/1 10 10.060 32 .01 0
10.08 0
6x
10.110 32 .010/ 13 0
32.010/12 0
32.090
10.100 /1 20 10 .12 0
10 .100 /130 10.040
32 .03 0
32 .12 0
d . 2
ee 32.080 t no
lf se
Oi ar
g/ ge
un y
o rg ta r
er s 31.010/13 0 ne
Ölv Pl a
- 31.010/120 2/
10 atz
e
s
31.010/11 0 ad
nr
ete
31 .02 0 l an
-P
32
in
31 .03 0 .1
t no
r se
ea
yg 40 .07 0
02 .05 0 ta r
02.070 la ne
P
1/ 40.050
tz
sa
2-
An
t rie
b/
In pu
t
31
-P
l an
e te
n ra d
40.100
40.100 /060
40 .120
40.030
eL 42 .20 0
42.22 0
0
40 .01 0
ic
40.160 /1 30 42 .24 0
40 .16 0/140
42.010
40 .16 0/1 10
rv
40 .16 0/1 20 4
o.
tn
se
ar
40 .14 0 ge
73.250 ry
n eta
Pla
40 .17 0 .3 4/
no a tz
et ds
a rs n ra
ge e te
Se
ry
eta l an
la n 75.300 -P
/P 42
3
tz
sa D
n ra d lut
ch
n e te /C
Pl a gD
- 75 .350 lun 70.220
40 Ku
pp 70 .16 0
75.330 73
-
70 .15 0
C
tch 70 .14 0
C lu
ZF
/
gC
p l un
up 70 .13 0
-K
75
70 .12 0
72.130
70.110
72.140
70 .10 0
70 .09 0 72 .12 0
70.08 0
70.070
72 .11 0
70.05 0
70.030 72.100
70 .010
A
ch B
l ut tch
/C lu
ng
A /C
B
pl u ng
up pl u
-K up
70 -K
72
14/11/21 8 HP 55 A 3.3/1
3.3.1 Assemble tower
Fit gearset 4, annulus (42.200) with

phase at the bottom in pot 1 (42.220).
Secure annulus with a new snap ring

(42.240).
10091
e
in
Insert pot 2 (73.250) into supporting
fixture 5X46.004.264.
Insert sun shaft (75.300) into pot 2.
Insert axial needle bearing (75.350) into

eL
sun shaft.
ic
rv
Se
10094
ZF
Align lined disks of clutch C before

insertion
Insert clutch C into sun shaft.
Fit combination bearing (75.330) on to

hub of internal multidisk carrier C.
10095
3.3/2 8 HP 55 A 14/11/21
Align lined disks of clutch E before
insertion.
Insert clutch E into sun shaft.
10096
e
in
Insert a new snap ring (40.070) into sun
shaft.
eL A clearance of approx. 15 mm must be

left from top of snap ring to end disk in
clutch E.
ic
rv
Se
10216
ZF
Fit annulus (40.050) in position shown in

sun shaft and secure it with a new snap
ring (40.030).
Fit needle bearing (40.120) with angle

washer (40.100/060) on clutch E.
10217
14/11/21 8 HP 55 A 3.3/3
Fit planetary support 3 (40.100) in
annulus.
Secure pot 2 with a new snap ring

(40.160/130).
Position snap ring and drive it in using

tool AA00.548.688 (see figure).
Take completed unit out of mounting

device.
10218
e
in
Place pot 1 in supporting fixture
5x46.004.264.
Place output shaft (42.010) in pot 1. eL

ic
rv
Se
13163
ZF
Fit completed pot 3 in pot 1 turning it.
10219
3.3/4 8 HP 55 A 14/11/21
Place needle bearing (40.010) with angle
washer on hub of planetary support.
Connect annulus 2 (40.160/120) and sun

gear 3 (40.160/110) and secure them with
a new snap ring(40.140).
Fit angle washer (40.160/140) in

sun gear 3.
Place unit in gearset 3.
10100
e
in
Place needle bearing (40.170) with
chamfered angle washer on the sun gear.
eL
ic
rv
Se
10101
ZF
Raise 5 new rectangular rings (32.080)

and 2 new rectangular rings (32.090)
onto input shaft (32.030) using tool
AA00.381.834.
Insert input shaft into supporting fixture

AA00.686.190.
Fit planet carrier 2 (32.010) onto input

shaft.
14014
14/11/21 8 HP 55 A 3.3/5
Secure planetary support with a new snap
ring (32.050).
Use assembly device 5x46.003.918.
Place oil collection tray (32.020) on

planetary support.
10103
e
in
Place angle washer (32.060) on planetary
support.
eL
ic
rv
Se
10104
ZF
Insert drive shaft into tower.
Fit needle bearing (32.010/120) with

angle washer (32.010/130) above drive
shaft.
10105
3.3/6 8 HP 55 A 14/11/21
Fit sun gear 1-2 (32.120) (with deep recess
at the bottom) in planetary support 2.
10106
e
in
Place planetary support (31.010) over sun
gear 1-2.
eL Place oil collection tray (31.030) on

planetary support.
ic
rv
Se
10107
ZF
Place needle bearing (02.050) with angle

washer on planetary support.
10220
14/11/21 8 HP 55 A 3.3/7
Pull pot 1 upwards.
Secure new snap ring (31.020) using tool

AA00.548.688.
10221
e
in
Place annulus (02.070) with caulked
angle washer on planetary support.
Insert shim (10.210). eL

ic
rv
Se
10223
ZF
3.3/8 8 HP 55 A 14/11/21
3.3.2 Assemble oil supply
Fit 2 new O-rings and new sealing

element to pump (10.040).
10070
e
in
Fit pump with chain (10.060) and chain
drive wheel (10.080) in intermediate
plate (10.010).
eL
ic
rv
Se
10071
ZF
Press pump firmly on intermediate plate

with tool 5x46.003.913.
The gap between pump and intermediate

plate is approx. 2 mm.
10073
14/11/21 8 HP 55 A 3.3/9
Fit intermediate plate in clamping device
AA00.602.553.
10076
e
in
Fit centering plate (10.100) and align it
using 14 through boreholes around its
circumference.
Place hold-down device on centering plate.

eL
Press centering plate with hold-down
ic
device by turning threaded spindle with a
tightening torque of 11 Nm.
rv
Se
13164
ZF
NOTICE
Section 1.3, see screw connection spe-
cification
Loosen the locking of the fixture.
Turn unit through 180° and secure it with

5 new screws (10.110).
10078
3.3/10 8 HP 55 A 14/11/21
Release tension by turning threaded
spindle.
Remove hold-down device.
Remove oil supply.
Turn screw (10.110) into intermediate

plate.
13166
e
in
Turn unit over.
Turn hexalobular screw (10.120) into

eL intermediate plate.
ic
rv
Se
13170
ZF
14/11/21 8 HP 55 A 3.3/11
3.3.3 Assemble brake A
Fit 2 new lip sealing rings (70.030,

70.050) on piston A (70.010).
Press piston A into oil supply

(cylinder A).
10080
e
in
Fit disk spring (70.070) into oil supply
(cylinder A).
Press in assembly bar 5x46.001.502

under mandrel press and secure it with
split ring (70.080).
eL
ic
rv
Se
10081
ZF
Fit angle washer (70.100) and needle

bear-ing (70.090) into oil supply
(cylinder A).
10082
3.3/12 8 HP 55 A 14/11/21
Position axial needle bearing (70.220) on
multidisk carrier (70.110).
Fit multidisk carrier into oil supply

(cylinder A).
10083
e
in
NOTICE
eL Insert multidisk package.
insert external disks (70.130) and lining
ic
Finally fit an end disk (70.150).
rv
Secure with a snap ring (70.160).

Se
10084
ZF
14/11/21 8 HP 55 A 3.3/13
3.3.4 Assemble brake B
Fit new O-ring (72.140) on intermediate

plate.
Fit piston B (72.100) with a new lip

sealing ring (72.110) and new pro le seal
(72.120) into intermediate plate.
10085
e
in
Fit cylinder B (72.130) over piston B into
intermediate plate.
Position centering lug of cylinder B in

roove in intermediate plate.
eL
ic
rv
Se
10086
ZF
Push in cylinder B until it is fully supported.
Piston B must protrude over cylinder B.
13128
3.3/14 8 HP 55 A 14/11/21
3.4 Install tower and oil supply in transmission
3.4.1 Install tower
14x
10.230
01.030
72.010
72.020
72.030
72.040
e
in
eL
ic
rv
Se
ZF
Turn transmission with converter side

faces upwards.
New transmission housing
Drive cylindrical pin (01.030) into

transmission housing using tool
AA00.615.414 for oil supply.
13301
14/11/21 8 HP 55 A 3.4/1
Rotate transmission housing by 180°.
Place tool AA00.596.017 on transmission

housing and lock it in place.
14052
e
in
Place tower lifter 5x46.003.957 on drive
shaft and secure it with slide.
Install tower with lifting device into

eL
Remove tower lifter.
ic
Remove tool AA00.596.017.
rv
Se
13167
ZF
NOTICE
Insert brake B:
Start with end disk (72.040), then insert
lining disks (72.030) and external disks
(72.020) alternately.
13168
3.4/2 8 HP 55 A 14/11/21
NOTICE
The tool shown below should be used
to prevent damaging the rectangular
rings.
To center rectangular rings, slide tool

AA00.549.949 over drive shaft to end
position.
Remove tool.
14021
e
3.4.2 Install oil supply
in
NOTICE
eL Insert oil supply in transmission housing
using lifting tool AA00.549.802 and
press it into position.
ic
rv
Se
13188
ZF
NOTICE
Section 1.3, see screw connection
specification
Secure oil supply with 14 new screws

(10.230).
13171
14/11/21 8 HP 55 A 3.4/3
Secure sealing device AA00.373.240
in position shown using 10 screws and
tighten them with a torque of 8.0 Nm
(± 0.8 Nm).
Press off clutches using a pneumatic gun

(see figure).
Remove sealing device.
13001
e
Alternative
in
Turn transmission housing over so oil
pan faces upwards.
Press off clutches using a pneumatic gun

(see figure).
eL
ic
rv
Se
10189
ZF
3.4/4 8 HP 55 A 14/11/21
3.5 Assemble mechatronic unit and oil pan
01.010
03.050
28.640 03.200
5x
28.570
e
03.010
in
12x
01.020 14x 03.030
28.450 03.010/015
28.580
eL 03 - Ölwa nne / Oil pan

ic
26.170
rv
28.670
28 - Mecha ntronisches Steuergerät

Mecha tronic control unit
Se
28.650
3.5.1 Install mechatronic unit

ZF
Turn transmission with control unit side

at top.
Fit new sealing sleeve (01.020) in

transmission housing (01.010).
Insert a new pressure tube (28.640) into

mechatronic unit.
13172
14/11/21 8 HP 55 A 3.5/1
Manual gearshift
Place tool AA00.603.510 on mechatronic

unit.
Position positioning switch and selector

lever with tool.
13176
e
in
Set selector shaft to position "N".
Position mechatronic unit.
Attach catch disk to mechatronic unit.

eL
Press mechatronic unit against transmis-
ic
sion housing to produce a positive con-
nection and remove tool.
rv
Se
13175
ZF
NOTICE
cification
Secure mechatronic unit with 14 new

screws (28.450).
13177
3.5/2 8 HP 55 A 14/11/21
Electric gearshift
NOTICE
cification
Position mechatronic unit.

Attach parking washer to mechatronic
unit. Press mechatronic unit against
transmission housing to produce a
positive connection. Secure mechatronic
unit with 14 new screws (28.450).
Remove selector shaft holding tool.
13144
e
in
Screw in 3 screws (28.570) on mecha-
tronic unit.
eL 2 screws on a transmission with oil

reservoir.
ic
rv
Se
10128
ZF
Fit speed sensor in groove in transmis-

sion housing and secure it with screw
(28.570).
10126
14/11/21 8 HP 55 A 3.5/3
Transmission with oil reservoir
Fit a new O-ring in delivery connection

from oil volume accu.
Insert oil volume accu in transmission

housing.
Screw in 1 screw (28.450) and 2 screws
(28.570) for oil volume accu.
Connect cable connector from oil volume

accu.
11005
e
in
Secure cable loom (26.170) to
transmission housing with screw (28.580).
eL
ic
rv
Se
13179
ZF
Fit a new guide sleeve (28.670) using

tool AA00.615.807 and turn it clockwise
as far as possible.
14011
3.5/4 8 HP 55 A 14/11/21
Secure guide sleeve with screw (28.650).
13181
e
3.5.2 Install oil pan
in
Fit oil filter (03.200) into mechatronic
unit.
eL
ic
rv
Se
13182
ZF
Fit securing pins 5x46.001.521 in

Position seal (03.050) over fixing pins

on sealing surface of transmission
housing.
13184
14/11/21 8 HP 55 A 3.5/5
NOTICE
specification

Place oil pan (03.010) over fixing pins.
Tighten 10 new torx screws (03.030) by

hand.
Pull out fixing pins.
Tighten 2 new Torx screws (03.030) by

hand in the fixing boreholes.
13186
e
in
Screw oil drain screw (03.010/015) into
oil pan.
eL
ic
rv
Se
13187
ZF
3.5/6 8 HP 55 A 14/11/21
3.6 Complete and install converter housing
35.220 35.230
35.190
35.150/120
35.180 35.400
35.150/110 35.120
35.110
35.090 35 - Vorderachsd iffere ntial
35.160
35.080 Front a xle d iffere ntial
35.172 35.070
10x 35.140 35.280
35.170 35.060/130
35.060/110
35.234
35.060
35.060/120 35.280
35.130 35.010
35.020
35.430
35.050
e
35.030
35.040
97 - Haltebügel
Ret aining clip 35.420
in
97.020/020 02.170
97.010 35.270
97.030
97.020/010 eL 14x
35.240 35.250
35.200/120
35.200/130
ic
35.200/140 35.210
rv
35.200/160
320 35.200/150
35.200/110
Se
3.6.1 Complete differential cover

ZF
Assemble small tapered roller bearing

(35.060/120) with press-on device
5x46.002.218 using mandrel press on
crown gear (35.060/110).
Turn over crown gear.
Assemble small tapered roller bearing

(35.060/130) with press-on device
5x46.002.218 using mandrel press on
crown gear (35.060/110).
09087
14/11/21 8 HP 55 A 3.6/1
3.6.2 Complete and install pinion shaft
Refer to Section 1.4.8.3 adjustment work
Place shim (35.090) on pinion shaft

(35.060).
Fit combination bearing (35.070) with

collar facing upwards.
09009
e
in
Press pinion shaft into combination bear-
ing using mandrel press.
eL
ic
rv
Se
09010
ZF
Insert pinion shaft into device

AA00.561.260.
09140
3.6/2 8 HP 55 A 14/11/21
Turn a new lock nut (35.080) by hand
on to pinion shaft to form a positive
connection and block it using hold-down
device AA00.561.262.
Tighten pinion shaft using socket wrench

AA00.561.169, reducer section and
torque wrench to nal torque.
Turn for left-handed thread clockwise and

right-handed thread counter-clockwise.
09141
e
3.6.3 Complete converter housing
in
1. Screw oil drain sealing screw (35.270)
into converter housing (35.010).
1.
eL 2. Place converter housing into holding
device 5x46.003.687.
ic
2.
rv
Se
13118
ZF
! CAUTION
Danger of burns
Heat converter housing on bearing seat

of the pinion shaft with a hot air blower.
Fit pinion shaft.
13190
14/11/21 8 HP 55 A 3.6/3
Secure pinion shaft with a snap ring
(35.110).
Fit snap ring with phase facing upwards.
Position pinion shaft with a sand hammer.
13191
e
in
Place insertion tool on plug-in toothing
on pinion shaft.
Place shaft sealing ring ring (35.120)

in tool AA00.679.163 and drive it into
converter housing.
eL
ic
Remove insertion tool.
rv
Se
13192
ZF
Turn device with differential opening is at

the top.
Insert a new shaft sealing ring (35.020)

using tool 5x46.004.262.
13194
3.6/4 8 HP 55 A 14/11/21
3.6.4 Install differential in converter
housing
2.
1. Fit shim (35.130) and bearing shell
(35.060/120) into converter housing.
2. Fit magnet (35.040) into hold-down

device (35.030) and secure it with torx
1. screw (35.050).
13196
e
in
Place differential cover (35.150/110) into
press-in device AA00.578.639.
eL Fit shaft sealing ring (35.150/120) into

press-in tool and press it into differential
cover.
ic
rv
Se
13197
ZF
Fit shim (35.140) and bearing shell

(35.060/130) into differential cover.
Fit round seal (35.160) on to differential

cover.
13200
14/11/21 8 HP 55 A 3.6/5
Insert differential into converter housing.
13202
e
in
NOTICE
specification

eL
ic
Hold bearing shell with your hand as you
insert differential cover.
rv
Position differential cover and secure it

with 10 torx screws (35.170) and 1 torx
screw (35.172).
Se
13203
ZF
Fit new snap ring (35.180) on output

ange (35.190).
Drive in output ange.
Tighten sealing screw (35.400).
13224
3.6/6 8 HP 55 A 14/11/21
3.6.5 Pre-assemble flanged shaft
Snap cover (35.200/120) (with welded

nuts facing upwards) over anged shaft
(35.200/110).
Fit ball bearing (35.200/130).
Press in using mandrel press with a

suitable tool.
13299
e
in
Secure ball bearing with a half-moon ring
(35.200/140) using tool 5x46.002.627.
eL
ic
rv
Se
13300
ZF
Position spring and tappet in flanged

shaft borehole and drive them in
carefully using a sand hammer.
14012
14/11/21 8 HP 55 A 3.6/7
3.6.6 Install converter housing on
transmission housing
Turn transmission with converter housing

side is at the top
Fit protective tube (35.220) with new

sealing ring (35.230) in transmission
housing.
13070
e
in
1. Fit a new sealing ring (01.060) in
transmission housing. 2.
2. Place new seal (35.234) on sealing
surface of transmission housing over
both bushes.
eL
ic
2.
rv
1.
Se
13214
ZF
Place converter housing on transmission

housing and align it.
Insert 14 new screws (35.240) into

interior of converter housing.
13216
3.6/8 8 HP 55 A 14/11/21
NOTICE
specification
Insert 1 new screw (35.250) outside

converter housing.
13215
e
3.6.7 Install converter and flanged
shaft
in
Drive shaft sealing ring ring (35.280)
into converter housing using tool
eL AA00.613.946.
ic
rv
Se
13223
ZF
Fit new O-ring (02.170) on drive shaft.
13217
14/11/21 8 HP 55 A 3.6/9
! WARNING
RISK OF ACCIDENT! The lifting and
moving of he avy parts without lifting
equipment can lead to damage to health
and sever e injuries.
ð Use a crane or similar lifting equipment.
Fit converter (22.320) with converter lifter

5X46.001.856 and crane in transmission
housing.
14051
e
in
Turn transmission with converter is at the
top.
Secure converter retaining bracket

(97.010) using screw (97.030) and secure
1 screw with hexagonal nut (97.020) to
eL
converter and transmission housing.
ic
rv

Se
13219
ZF
Place flanged shaft in the converter

housing and secure it with 3 new t orx
screws (35.210).
13221
3.6/10 8 HP 55 A 14/11/21
Drive vent tube (35.420) flush
into converter housing using tool
5x46.003.018.
Fit vent cover (35.430) into vent tube.
13302
e
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A 3.6/11
ZF
Se
rv
ic
eL
in
e
3.7 Assemble front axle output
37 - Vorderachsabtrieb / Front axle out put

37 .100
4x
37.20 0
37. 010/110
38.41 0
4x
37.32 0 38.40 0
2x 37.01 0/16 0 37.34 0
37.020
11x
37.01 0/130 37.300
37. 010/140 37.340
37 .010 /150
37.070/11 0
37.26 6
37.250 37.070/130
37.120/140 37.270
37.280
e
37 .240
37.12 0/13 0
37.120/110
37.14 0/130
in
37.22 0
37 .120 /120
37 .120 /150
eL 37 .140/120
37.14 0/14 0
ic
37 .140 /150
37.140 /110
rv
37.04 0/13 0
37.04 0/12 0
37 .040 /110
37.04 0/14 0
Se
37.05 0
37 .030
3.7.1 Complete intermediate housing

ZF
! CAUTION
Danger of burns
Heat bearing seats with a hot air blower.
New intermediate housing

Press new bearing shells (37.120/130,
37.140/150) into intermediate housing
(37.070/110) using tool AA00.600.587.
14018
14/11/21 8 HP 55 A 3.7/1
Fit pump annulus into pump (37.100) and
secure pump with 4 screws (37.200) in
intermediate housing.
13303
e
3.7.2Prepare transmission housing,
assemble side shaft
in
NOTICE
Fit shim S5 (37.240).

eL
Drive bearing shell (37.120/120)
ic
into transmission housing using tool
AA00.625.669.
rv
Se
13305
ZF
NOTICE
Fit oil supply (37.030) into transmission

housing.
Fit shim S4 (37.050) and drive in

bearing shell (37.040/140) using tool
5x46.003.834.
13308
3.7/2 8 HP 55 A 14/11/21
Fit side shaft (37.010 (110) in press-on
device 5x46.003.738.
Fit retaining plate (37.010/130).
Press on ball bearing (37.010/140) using

tool 5x46.003.738 with mandrel press
AA01.072.185.
Secure ball bearing with a snap ring

(37.010/150).
09064
e
in
Place protective sleeve on connection
shaft (37.010/160).
eL Press connection shaft on to side shaft

ic
rv
Se
09065
ZF
Place side shaft in transmission housing

and secure it with 2 screws (37.020).
13309
14/11/21 8 HP 55 A 3.7/3
3.7.3 Complete drive wheel
Position drive wheel (37.120/110) on tool

5x66.000.075.
Press large tapered roller bearing

(37.120/130) on to drive wheel using
tool AA00.622.346 with mandrel press
AA01.072.185.
13315
e
in
Turn drive wheel through 180°.
Place tool 5x46.004.033 on drive shaft.

eL
ic
rv
Se
13319
ZF
Position shaft sealing ring (37.120/140)

(with flat side facing upwards) over tool
on drive wheel.
13321
3.7/4 8 HP 55 A 14/11/21
Remove tool.
Position drive wheel on tool

5x66.000.075.
Press small tapered roller bearing

(37.120/120) on to drive wheel using
tool AA00.621.827 with mandrel press
AA01.072.185.
13322
e
in
Remove drive wheel from tool.
Turn drive wheel over.

eL Fit disk spring (37.250) in drive wheel
borehole.
ic
rv
Se
13325
ZF
Position tool 5x46.004.034 between shaft

sealing ring and drive wheel.
13326
14/11/21 8 HP 55 A 3.7/5
3.7.4 Complete output gear
Press tapered roller bearing (37.140/150)

on to output gear (37.140/110) using
5x46.003.711 and mandrel press.
09042
e
in
Press in small needle sleeve (37.140/120)
into drive wheel using tool 5x46.003.711
and mandrel press.
Press in small needle sleeve (37.140/130)

into drive wheel using tool 5x46.003.711
eL
and mandrel press.
ic
Secure it with a snap ring (37.140/140).
rv
Se
09041
3.7.5 Complete front axle shaft

ZF
Press small tapered roller bearing

(37.040/140) on to front axle shaft
(37.040/110).using tool AA00.600.703
and mandrel press.
Press small needle sleeve (37.040/120)

(with lettered side facing upwards) into
mandrel of tool AA00.600.703 and
press it into front axle shaft (small
diameter) using mandrel press.
14018
3.7/6 8 HP 55 A 14/11/21
Connect needle bearing (37.040/130) to
front axle shaft.
Fit output gear on to front axle shaft.
09043
e
3.7.6Assemble drive wheel. front
axle shaft and output gear
in
NOTICE
eL Fit shim S6 (37.220) over output shaft.
ic
rv
Se
13328
ZF
Press drive wheel into transmission

housing using tool. Tool 3 times each
rotate by 90° so that shaft seal is in
position.
The tool must be on sealing surface of

Remove tool.
13327
14/11/21 8 HP 55 A 3.7/7
Block drive wheel by activating parking
lock.
13329
e
in
Secure drive wheel with screw (37.266).
eL
ic
rv
Se
13330
ZF
Fit front axle shaft with output gear

using auxiliary tool 5x46.003.843 in
09067
3.7/8 8 HP 55 A 14/11/21
Drive 2 clamping sleeves (37.340)
approx. 1 mm beyond sealing surface of
13348
e
in
1. Position new seal (37.280) on sealing
surface.
eL
2. 2. Align hexagonal secondary pump in
intermediate housing with side shaft
hexagon.
ic
rv
2.
1.
Se
13349
ZF
Fit magnet (37.270) in recess of

09069
14/11/21 8 HP 55 A 3.7/9
Position intermediate housing and press
it secured on to transmission housing.
Drive in adjusting pin flush with housing.
13351
e
in
NOTICE
specification
Secure intermediate housing with 4

eL
hexalobular screws (37.320) and 11 new
ic
aluminum torx screws (37.300).
rv
Se
13352
ZF
Screw oil drain screw in rear axle output

(37.070/130) into intermediate housing.
13353
3.7/10 8 HP 55 A 14/11/21
3.8 Assemble rear axle output
36.040
6x
36.080
36.010
36.120
36.070
36.050
38.180
38.170
e
36.070
in
36.020
36.030
36.060
pu
t
eL
e ou t
axl
ic
ar
/ Re
ieb
sa btr
h
rac
rv
Hinte
-
36
Se
3.8.1 Prepare and assemble

distribution housing
ZF
Press ball bearing (36.030) into

distribution housing (36.010) using tool
and mandrel press.
13344
14/11/21 8 HP 55 A 3.8/1
Secure ball bearing with a new snap ring
(36.060).
13358
e
in
Insert a new shaft sealing ring (36.020)
using tool AA00.578.569.
eL
ic
rv
Se
13356
ZF
Press in plug-in shaft (36.040) with the

vibration damper using mandrel press.
13357
3.8/2 8 HP 55 A 14/11/21
Secure plug-in shaft with a new snap ring
(36.050).
13028
e
in
Screw new rear axle output oil filler plug
(36.120) into transmission housing.
eL Fit new O-ring (36.070) on distribution

housing.
ic
rv
Se
13355
3.8.2 Complete and assemble the rear

axle output
ZF
Fit differential (38.170) with ball bearing

(38.180) in intermediate housing.
13354
14/11/21 8 HP 55 A 3.8/3
Position and align distributor cover on
intermediate housing with oil filler plug
is flush with side shaft.
13360
e
in
NOTICE
cification

eL
Secure distributor cover and intermediate
ic
housing with 6 new aluminum screws
(36.080).
rv
Se
13368
Transmission without vibration damper

ZF
Guide spray ring (36.070) over plug-in

shaft and clip it in.
13a10
3.8/4 8 HP 55 A 14/11/21
Transmission with bending vibration
damper
1. Guide spray ring (36.070) over plug-in
shaft and clip it in.
2. Place vibration damper (36.090) on

distribution housing.
3. Secure vibration damper with 3 new

coated screws (36.100).
13a09
e
in
Drive vent tube (38.400) into
intermediate housing using tool
5x46.003.018.
eL Press vent cover (38.410) into vent tube.
ic
rv
Se
13366
ZF
14/11/21 8 HP 55 A 3.8/5
ZF
Se
rv
ic
eL
in
e
Revisions
Rev A Date of document creation 2014/04/04
Rev B Corrections in Chapter Adjustment work 2014/06/05
Phrase reuni cation für english translation
Rev C Update screw connection specification 1.3/1 - 1.3/2 2014/11/21
differential cover, converter housing and guide
plate
Update tightening torque nut pinion shaft 1.5/1
Various changes in the document 1.4/25, 1.4/28, 1.4/30,

2.2/1, 2.2/7, 2.3/4,
2.3/6, 2.3/9, 2.5/3,
3.1/1, 3.1/2, 3.1/3,
e
3.1/5, 3.4/2, 3.5/3,
3.6/3, 3.6/9, Kap. 3.7
in
eL
ic
rv
Se
ZF
14/11/21 8 HP 55 A XI
ZF
Se
rv
ic
eL
in
e
ZF
Se
rv
ic
eL
in
e
ZF Friedrichshafen AG
ZF Services
t er Str.
66117 Saarbrücken
Deutschland/Germany
Telefon: +49 681 920 0
www.zf.com
Order-N o. 1087 751 103

Versi on 14/11/21 - C
Presented by:
e
in
eL
ic
rv
Se
ZF
Driveline and Chassis Technology

8HP55A

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Reparaturanleitung

© Copyright 2014, all rights reserved and published by

1.1 Illustration of transmission 1.1/1

1.2 Power flow diagram 1.2/1

1.3. Screw connection specifications 1.3/1

1.4 Adjustment work 1.4/1

1.4.8 Bevel gear (front axle differential) 1.4/25

1.5 Tightening torques 1.5/1

1.6 Transmission test 1.6/1

1.7 Special tools 1.7/1

1.8 Oil flow diagram 1.8/1

2.1 Preparations 2.1/1

2.2 Transmission clearance and front axle output 2.2/1

2.4.2 Remove mechatronic unit

2.5.2 Dismantle oil supply 2.5/1

2.6 Remove and dismantle tower 2.6/1

2.7 Remove clutches 2.7/1

3.1 Preparations 3.1/1

3.2 Kupplungen montieren 3.2/1

3.3 Assemble tower and oil supply 3.3/1

3.4 Install tower and oil supply in transmission 3.4/1

Complete and install converter housing

3.6.5 Pre-assemble anged shaft 3.6/7

3.7 Assemble front axle output 3.7/1

3.7.4 Complete output gear 3.7/6

3.8 Assemble rear axle output 3.8/1

A separate manual is planned for the mechatronic unit.

Herth Reus Stubauer

1.3.1 Mechatroni c unit types M and E

12 See section 1.5 for tightening torques.

See section 1.5 for tightening torques.

1.3.3 Differential cover

Tighten 11 screws on intermediate

Sequence Screw Tightening torque

1 10, 5 4,0 ± 1,0 Nm

Special feature: Screw 10 with coating

See section 1.5 for tightening torques.

Tighten 6 screws on distribution housing

Tighten 15 screws on intermediate

Sequence Screw Tightening torque

1.3.6 Converter housing

Tighten 15 screws on converter housing

1 3 Tighten 14 screws on distribution housing

See section 1.5 for tightening torques.

1.3.9 Guide plate

See section 1.5 for tightening torques.

Tighten guiding plate screws according

Sequence Screw Tightening torque

1 3 Tur n in, 2- 4 turns

2 1 -3 10,0 Nm (± 1,0 Nm)

Place the 2 spacers 5p01.000.329 on

Tighten the 4 knurled screws

Connect measuring plate 5p01.040.330 to

Clamp the disk cluster to be measured

Place measuring foot of dial gage in

Move measuring beam down to base

Read measurement  MX*

*Index X stands for inserted multidisk

(Adjustment specification 1087.700.135)

Multidisk package consists of following: