ZF-AS Tronic

in Trucks
Dirk Stemme / LKS-T dept.
ZF Friedrichshafen AG
 ZF-AS Tronic
Agenda

 Volumes
 Splitter group synchronization
 Transmission brake
 Tappet / Neutral switch
 Shift fork
 Gears
 Pressure relief valve (PRV)
 Release bearing
 Clutch release mechanism
 Software

© Copyright ZF Friedrichshafen AG
 Transmission actuator

07_2_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic
Volumes
100.000
16-speed ACTUAL BP 11/06
90.000 12-speed, long
12-speed, short
80.000

70.000
Stückzahl / Volume

60.000

50.000

40.000

30.000

20.000

10.000

© Copyright ZF Friedrichshafen AG
0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Produktionsjahr / Production Year

07_3_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L05/13 (SI 16_06); S/G Synchronization
 Description of error / Cause
S/G change-over error (FC 149).
Irregular contact pattern at the contact face
of the S/G plate to the synchronizer ring.
 Measures / Remedy / Solution
New S/G plate no.: 1328 302 132 was
introduced
(as of 06/2006; serial no.: 386916)
in order to ensure a smooth contact face at all
limit positions (enlargement of the
locking faces and thus also of the cam
recesses).
Pay attention to SI 16_06.
 Responsibility / Warranty
Warranty claim is accepted.
 Damage coding
Primary defective part: Plate no.: 1328 302 109
Location of damage: 953 (locking tooth)

© Copyright ZF Friedrichshafen AG
Location of damage: 768 (worn)
Cause of damage: 048 (design change)

07_4_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L06/33; Transmission Brake
 Description of error / Cause
Piston at transmission brake molten (IVECO).
3 vehicles known where the damage has
re-occurred at regular intervals (up to 1 year).
Currently the error cause is not yet known.
 Measures / Remedy / Solution
For the time being, no remedial action(s)
defined. Datalogger measurements
to be effected.
 Responsibility / Warranty
Until final determination of cause and
responsibility, all warranty applications filed
are accepted.
 Damage coding
Primary defective part: Piston no.: 1328 302 095
Location of damage: 868 (piston)

© Copyright ZF Friedrichshafen AG
Location of damage: 359 (overheated)
Cause of damage: 034 (overload)

07_5_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L04/24 (SI 08_06); Tappet / Neutral Switch
 Description of error / Cause
Vehicle cannot be started (DAF, USA).
Loose, fractured, or tilted contact bridge
(also applies to Ecosplit transmissions).
 Measures / Remedy / Solution
New switch no.: 0501 215 297 introduced by
the company Delphi
(as of: 04/2006; serial no.: 376345).
Pay attention to SI 108_06.
 Responsibility / Warranty
Warranty claim is accepted.
 Damage coding
Primary defective part: Switch no.: 0501 210 059
Location of damage: 546 (contact)
Type of damage: 224 (No contact)
Cause of damage: 206 (electr. defect)

© Copyright ZF Friedrichshafen AG
Cause of damage:
Distinctive marking:
Parts number at the socket

07_6_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L04/24 (SI 08_06); Tappet / Neutral Switch
 Damage patterns: Contact bridge

loose fractured tilted

© Copyright ZF Friedrichshafen AG
07_7_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic – Fault Finding & Troubleshooting
L04/24 (SI 08_06); Tappet / Neutral Switch
 New switch no.: 0501 215 297

Contact bridge
made from bronze
material tempered
Distance ring for stress-relief
NEW

© Copyright ZF Friedrichshafen AG
Improved
rivet shape

07_8_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L06/27; Shift Fork
 Description of error / Cause
Shift fork worn at contact point to
sliding sleeve/ selector sleeve.
Shift forks without molybdenum coating (does
not affect the error cause “water in oil”).
 Measures / Remedy / Solution
Installation of monitoring systems
in production (already implemented to some
extent).
 Responsibility / Warranty
Warranty application is accepted.
 Damage coding
Primary defective part: Shift fork
12-speed: 1327 306 007 (1/R);
1328 306 026 (2/3)
16-speed: 1328 306 026 (1/2, 3/4);
1328 306 033 (R)
Location of damage: 949 (shift fork)

© Copyright ZF Friedrichshafen AG
Type of damage: 768 (worn)
Cause of damage: 212 (manufacturing
defect)

07_9_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – no Fault Finding &
Troubleshooting; Gears
 Description of error / Cause
Plastic deformation of gears (MAN).
Overheating. Until date, 5 cases known.
 Measures / Remedy / Solution
So far, no remedial action(s) have been
defined. Until date, no unique cause has
been identified for the defect.
Datalogger measurements to be effected.
 Responsibility / Warranty
Until final determination of cause and
responsibility, all warranty claims filed are accepted.
 Damage coding
Primary defective part: Gears of the main shaft (K1, K2 / 3, 2, 1, R)
Gears of the countershaft

© Copyright ZF Friedrichshafen AG
Location of damage: 202 (meshing gears)
Type of damage: 729 (plastic deformation)
Cause of damage: 049 (overheating)
07_10_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic – no Fault Finding &
Troubleshooting; Pressure Relief Valve (PRV)
 Description of error / Cause
PRV leaking.
Black, sticky deposits
(oil deposits from the compressor);
damaged seal(s).
Possibly further causes.
 Measures / Remedy / Solution
So far, no remedial action(s) have been defined.
Inspections at the suppliers and the
vehicle manufacturers still last.
 Responsibility / Warranty
Until final determination of cause and responsibility,
all warranty claims filed are accepted.
 Damage coding
Primary defective part: PRV no.: 0501 320 849
Location of damage: 389 (main pressure valve)

© Copyright ZF Friedrichshafen AG
Location of damage: 800 (leaking)
Cause of damage: 027 (oil contamination)

07_11_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L05/20; Release Bearing
 Description of error / Cause
Release bearing has fallen apart.
Lack of lubricant due to increase in
ingress of particles.
 Measures / Remedy / Solution
New release bearing with bearing sealant
(paste) (locking grease) and extended
guide bush by ZF Sachs were introduced
(as of 11/2006 in CW46/2006).
 Responsibility / Warranty
Warranty application is accepted.
 Damage coding
Primary defective part: Release bearing
Location of damage: 064 (pressure bearing)

© Copyright ZF Friedrichshafen AG
Type of damage: 222 (fallen out)
Cause of damage: 287 (lack of lubricant)

07_12_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic – Fault Finding & Troubleshooting
L05/20; Release Bearing with roll

NEW Interim status OLD

0501 215 566 0501 215 165 0501 215 086
Bearing sealant
paste
(locking grease)

Extended
guide bush

With bearing sealant paste (locking Without bearing sealant paste Without bearing sealant paste
grease) (locking grease) (locking grease)
With extended guide bush With extended guide bush Without extended guide bush
As of CW46/2006
CW03/2006 until CW45/2006 Until CW02/2006

© Copyright ZF Friedrichshafen AG
07_13_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic – Fault Finding & Troubleshooting
L05/20; Release Bearing without roll

NEW Interim status OLD

0501 215 567 0501 213 678
Bearing sealant
paste
(locking grease)

Extended
guide bush

With bearing sealant paste (locking NO interim status available! Without bearing sealant paste
grease) (locking grease)
With extended guide bush Without extended guide bush
As of CW46/2006
CW06/2003 until CW45/2006

© Copyright ZF Friedrichshafen AG
07_14_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic
Release Bearing

NEW release bearing with bearing sealant paste (locking grease)

 IVECO is not affected because the release bearings are not included in the
scope of supplies of ZFF.
 Advantage of “bearing sealant paste (locking grease)”:
Additional protection of the bearing from dirt.
 Advantage of “Extended guide bush”:
The gap between the bearing and the sliding sleeve has been covered, thus,
the shed-off dirt is no longer caught there.
 Release device with roller:
Cast blank has been modified due to cost reasons, as of release bearing no.:
0501 215 086 to release bearing no.: 0501 215 165 and/or 0501 215 566.
- Anti-rotation device has been optimized with reference to the material used;

© Copyright ZF Friedrichshafen AG
- Abutment with release fork has been optimized with reference to the
material used and the machining process.

07_15_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic
Clutch Release Mechanism
Without
Customer With roll Comment
roll

Until As of
MAN Change of Parts List (BoM)
CW27/2006 CW27/2006

Until As of
DAF Change of Parts List (BoM)
CW25/2005 CW25/2005

New parts lists, since the release

Until As of
Iveco bearing is not part of ZF’s scope of
CW45/2006 CW45/2006
supplies (logistics).

Until AS Tronic supplies have been

RVI -
CW38/2006 phased out.

© Copyright ZF Friedrichshafen AG
Until As of
FreedomLine Change of Parts List (BoM)
CW09/2006 CW09/2006

07_16_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic
Clutch Release Mechanism

Grease: Clutch release mechanism with and without roll

 Documentation made available on the ServiceLine (at the point of drawing
up this presentation, documentation was not finalized yet).

© Copyright ZF Friedrichshafen AG
07_17_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic
Clutch Release Mechanism

Proceedings in the complaint case: “Harsh Engagement“

(updated version of the slide from Annual Technical Seminar 2005)
1. Remove release fork, assess release mechanism’s parts (do not remove transmission):
- If these were found OK, then clean, grease, and re-install the release parts in
accordance with SI 16_04c.
- If these were found not OK, then replace the release fork and shaft (clean and
grease).
2. If the problems are not eliminated by the activities listed under Item 1:
- Remove transmission, remove and assess the release bearing.
- Assess the release unit’s guide tube, the input shaft, the pilot bearing, and the clutch.
– Install “NEW release mechanism with roll“
(only for DAF, MAN, and Iveco vehicles).
3. If the problems are not eliminated by the activities listed under Item 2:

© Copyright ZF Friedrichshafen AG
- Replace clutch (recommendation: NO reworked clutches.)
4. Do not furnish “swing units” without roller release device.

07_18_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic
Software
Vehicle Software
No. OEM Status Comment
Engine Transmission PAK Version Introduction
Volume
1 MAN Euro 3/4: D08 AS Tronic mid 8 V34_5e3 Beginning 2006
production
2 MAN Euro 4: D08 AS Tronic mid E8 V34_13h 03/2006 Planning Pak E8 as of > V34_5
Euro 3:
D2066CR, D2066CR ASF; Volume
3 MAN AS Tronic 2 5 V31_13o
D2866, D2866 ASF; D2876; production
D2876CR
Euro 3: Remedy Fault Finding &
D2066CR, D2066CR ASF; Volume Troubleshooting error 124
4 MAN AS Tronic 2 5 V31_13p 01.09.2005
D2866, D2866 ASF; D2876; production Check phase during engine ramp-up,
D2876CR cold start
Volume
5 MAN Euro 4/5 (OBD) AS Tronic 2 8 V34_5e3 April 2006
production
Pak E8 will be skipped.
MAN enforces KLL (German
6 MAN Euro 4/5 (OBD) AS Tronic 2 9 V35_x 2008 Planning
abbreviation for Clutch Characteristic
Curve) as of Pak9
7 MAN Euro 5 (OBD) AS Tronic 2 9 V35_3 01/2007 Testing B level for winter test
Volume
8 MAN Euro 4 (military + off-road) AS Tronic 2 E8 V34_13e end of 2006 Off-road applications
production
9 MAN Euro 4 (military + off-road) AS Tronic 2 E8 V34_13h 03/2006 Planning Off-road applications
Volume
10 DAF Euro 3: XEC/PEC engine AS Tronic 2 7 V33_7a KW25/2005
production
Volume
11 DAF Euro 3: XEC/PEC engine AS Tronic 2 7 V33_7a2 KW49/2005
production
Volume
12 DAF Euro 4/5: PR/MX engine AS Tronic 2 8 V34_5e5 KW21/2006 No solution for FC149 + FC155
production
SW solution for FC149 + FC155
13 DAF Euro 4/5: PR/MX engine AS Tronic 2 E8 V34_13c KW13/2007 Planning
with LL rattle function S/G K1/K2
Project 10.830
14 DAF Euro 4/5: PR/MX engine AS Tronic 2 E8 V34_16a KW29/2007 Planning C level for field test
with Auto/Auto function
15 DAF Euro 4/5: MX engine (terrain) AS Tronic 2 E8 V34_16a Mid-2007 Planning Off-road application
Volume
16 Iveco Euro 3 AS Tronic 2 7 V33_4b1 in 2004
production
Volume
17 Iveco Euro 4 prioritized (Anticipo) AS Tronic 2 7 V33_4b3 03/2005
production
Volume
18 Iveco Euro 4/5 AS Tronic 2 E8 V34_11b3 09/2006 Off-road application: Trukker
production
Volume
19 Iveco Euro 4/5 AS Tronic 2 E8 V34_11b6 09/2006 Stralis; Trukker as of 02/2007
production
20 Iveco Euro 4/5 AS Tronic 2 9 V35_x End of 2007 Planung Stralis; Trukker

© Copyright ZF Friedrichshafen AG
Cummins; Detroit Diesel;
Volume
21 USA / Freedomline Caterpillar; MB4000 (OM407 R6); AS Tronic 2 6 V32_4c Mid-2004
production
Mack; Western Star
Cummins; Detroit Diesel;
Field test ended
22 USA / Freedomline Caterpillar; MB4000 (OM407 R6); AS Tronic 2 6 V32_4d1 Beginning 2007 Planning
Application for 2007 engines
Mack; Western Star
Cummins; Detroit Diesel;
23 USA / Freedomline Caterpillar; MB4000 (OM407 R6); AS Tronic 2 6 V32_4e Beginning 2008 Planning
Mack; Western Star

07_19_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic
Transmission Actuator

News and information on the TA3 and TA3.3 repair kits

 Also refer to the presentation by Frank Schelkle, BKS-R dept.

© Copyright ZF Friedrichshafen AG
07_20_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
Thank you very much for your
attention!
Dirk Stemme, LKS-T dept.
ZF Friedrichshafen AG
Backup

Dirk Stemme, LKS-T dept.

ZF Friedrichshafen AG
 ZF-AS Tronic (From the Annual Technical
Seminar 2005) Clutch Release Mechanism

With roll

Roll pressed in with

plastic bush (low friction).

© Copyright ZF Friedrichshafen AG
New PTFE bearing Hardened contact faces
bushes (larger play). (anti-rotation device).

07_23_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

 ZF-AS Tronic (From the Annual Technical
Seminar 2005) Clutch Release Mechanism

Guide bush aligned;

Without roll Cast blank modified;
Implementation: March 19, 2004

Contact faces optimized;

Implementation: October
12, 2004

Fork ends enlarged;

Inner faces hardened;
Implementation: June 15,
Surface roughness max. Rz16; 2004
Diameter tolerance -0.07
Implementation: March 01, 2004

© Copyright ZF Friedrichshafen AG
DU bush greased;
Implementation: December 15,
2003
07_24_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic (From the Annual Technical
Seminar 2005) Clutch Release Mechanism

Without roll: 1328 268 003 With roll: 1328 268 006
Cams
greased

Bush PA 6.6
maintenance-
Bush P20
free
greased
30 % glass
fiber
15 % PTFE
Roll with slide/plain (polytetrafluoro
bearing ethylene)
maintenance-free
Shaft seal Backlash
compensation: 0.3 mm
Without shaft sealing
ring

© Copyright ZF Friedrichshafen AG
07_25_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic
 ZF-AS Tronic (From the Annual Technical
Seminar 2005) Clutch Release Mechanism

 Advantages of roller release mechanism:

 Interface to volume production remains unchanged (connecting plate, pressure rod
length).
 Optimized release fork with reference to center of gravity, weight, strength, service
lifetime.
 Maintenance-free (no greasing during operation).
 Improved clutch actuation function thanks to reduced friction.
 Disadvantages of roller release mechanism:
 NEW release fork can only be used with the NEW release bearing.
 Note:
 Release shaft has play with the release fork i.e. this no longer constitutes a reason for
complaint.
 Parts numbers:
 Release fork
with roll no.: 1328 268 010 / without roll no.: 1328 268 003

© Copyright ZF Friedrichshafen AG
 Release bearing
without bearing sealant paste: with roll no.: 0501 215 165 / without roll no.: 0501 213
678
with bearing sealant paste: with roll no.: 0501 215 566 / without roll no.: 0501 215 567
 Release shaft
07_26_en_Stemmewith roll no.: 1328 368
Annual 001 / without
Technical Seminarroll
2007no.: 1328 Tronic
• ZF-AS 368 001
 ZF-AS Tronic (From the Annual Technical
Seminar 2005) Clutch Release Mechanism

 Definition of “Harsh Engagement“:

“Jerk when engaging a starting gear during standstill.”
 Error code for “Harsh Engagement“:
- F114 (F72hex)
- “Clutch closes accidentally when vehicle is stationary with gear engaged.”
 Complaint:
- Harsh gear engagement behavior when engaging a starting gear.
- Bad maneuvering behavior.
- No jerk-free setting off possible.
 Cause of fault:
Stick-Slip effect (due to fretting corrosion and dry surfaces).
The clutch is lightly tightened in order to free a tooth-on-tooth position during
the shift process while the vehicle is stationary. During this process, clutch

© Copyright ZF Friedrichshafen AG
torque may occur which, during the final engagement process of the gear,
causes the jerk.

07_27_en_Stemme Annual Technical Seminar 2007 • ZF-AS Tronic

Vielen Dank für
Ihre Aufmerksamkeit!
Dirk Stemme / LKS-T dept.
ZF Friedrichshafen AG