16S151-16S181 16S221-16S251 Planetary Gear with HELICAL TEETH

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1 ZF EcoSplit Models 16S151-16S181 16S221-16S251 Planetary Gear with HELICAL TEETH 04/2008 File ZFE0023.Pdf

2 1 Z.F. EcoSplit III 6S151 to 16S25 6S251 From 16S1 suitable to : Planetary Gear with HELICAL TEETH Application 16S151 16S181 16S221 16S251 MERCEDES MAN IVECO RVI DAF VOLVO Ratios R.13,74-0,84 R.13,80-0,84 R.16,41-1,00 A B C 16S151 16S181 16S221 16S251 (1315) (1316) (1316) (1316) Technical Data 023 /

3 Suitable To : ZF 2 Gearbox Models 16S151-16S181-16S221-16S251 Input Shaft 7 11 Gasket Kit Main Shaft Springs & Slides Kits x 3 x 3 Kit Oil Seal Kit Only with WSK WITH Oil Pump integrated in the Front Cover 2nd (#) Synchro Rebuilt Kit 4th / 3rd Fig. 33/34/35/36/21/22 78 (@) Synchro Rebuilt Kit 1st / 2nd Fig. 50/51/52/53/21/ Old Const th 30 New Double Cone Synchronization (Except 16S251) Old Countershaft & Reverse Shaft New WITHOUT Oil Pump integrated in the Front Cover Const Ratios 16S151 A :13,74-0,84 B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S181 A :- B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S221 A :13,74-0,84 B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S251 A :-- B : 13,80-0,84 C : -- D :-- E: H L st 3rd Single Cone Synchronization Only Latest Models 65 4th rd RG (#) HELICAL TEETH RG 1st 2nd 68 RG (@)

4 O.E.M. Reference Cover Rotor Oil Pump Housing Front Cover Bush Oil Seal 30x37x Front Cover Front Cover Cover Housing Front Cover Front Cover Front Cover Front Cover Front Cover 1 With WSK Front Cover Front Cover Rotor Oil Seal 55x75x Oil Seal 52x68x8 1 (1) Oil Seal 52x72x8 1 (2) Bearing 52x90x33 1 (2) Disk 1 (1) Bearing D.85x150x30, Constant Gear 34 T 1 A Constant Gear 35 T 1 B Constant Gear 30 T 1 C Constant gear 35 T 1 B Constant Gear 30 T 1 C Constant Gear 34 T 1 A Constant Gear 35 T 1 B Constant Gear 30 T 1 C Synchronizer Cone Synchronizer Ring 2 Old Synchronizer Ring 2 New Input Shaft 1 L=125 H=31, Input Shaft 1 L=102 H= Input Shaft 1 With WSK Input Shaft 1 NMV221 (Clutch PTO) Input Shaft 1 L=134 H= Input Shaft Input Shaft 1 L=63 H=46,5 / WSK Input Shaft Input Shaft 1 NMV221 (Clutch PTO) Pressure Piece 3 (1) Only for Input S (2) Only for Input S (3) Old. Replaced by 1 pc. fig pc. fig. 74 (*) New Models only. Do NO MIX Single Cone Synchron. with Double Cone Synchron. (#) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig. 79 (@) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig / A

5 O.E.M. Reference Spring D.6,50x23, Sliding Sleeve Synchronizer Cone Roller Cage D.42x40, Ring 1 S.8,00 mm Ring 1 S.7,50 mm Thrust Washer 81,5x Bush 67x77x54, Bush D.67x77x66, Roller Cage 77x101x Roller Cage D.77x101x Gear 4th Speed 30 T 1 A Gear 4th Speed 32 T 1 BC Gear 4th Speed 30 T 1 A Gear 4th Speed 32 T 1 BC Synchronizer Cone Synchronizer Cone 2 (#) Synchronizer Ring 2 Old Synchronizer Ring 2 New Synchronizer Ring 2 (#) Synchronizer Hub Synchronizer Hub 1 (#) Sliding Sleeve Sliding Sleeve 1 (#) Gear 3rd Speed 32 T 1 A Gear 3rd Speed 34 T 1 BC Gear 3rd Speed 34 T 1 BC Gear 3rd Speed 32 T 1 A Gear 3rd Speed 34 T 1 BC Gear 3rd Speed 34 T 1 B Needle Cage D.92x100x Needle Cage D.92x100x Main Shaft Main Shaft Main Shaft Gear 2nd Speed 37 T 1 A Gear 2nd Speed 38 T 1 BC Gear 2nd Speed 37 T 1 A Gear 2nd Speed 38 T 1 BC Synchronizer Cone Intermediate Ring Intermediate Cone Synchronizer Ring Synchronizer Hub Sliding Sleeve 1 (1) Only for Input S (2) Only for Input S (3) Old. Replaced by 1 pc. fig pc. fig. 74 (*) New Models only. Do NO MIX Single Cone Synchron. with Double Cone Synchron. (#) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig. 79 (@) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig / A

6 O.E.M. Reference 5 (1) Only for Input S (2) Only for Input S (3) Old. Replaced by 1 pc. fig pc. fig. 74 (*) New Models only. Do NO MIX Single Cone Synchron. with Double Cone Synchron. (#) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig. 79 (@) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig Pad Synchronizer Cone 2 (*) Synchronizer Cone 2 (@) Synchronizer Ring 2 (*) Old Synchronizer Ring 2 (*) New Synchronizer Ring 2 (@) Synchronizer Hub 1 (*) Synchronizer Hub 1 (@) Sliding Sleeve 1 (*) Sliding Sleeve 1 (@) Needle Cage D.96x104x Needle Cage D.96x104x Bush Bush D.85x96x Gear 1st Speed 44 T 1 A Gear 1st Speed 47 T 1 BC Gear 1st Speed 44 T 1 A Gear 1st Speed 47 T 1 BC Engaging Ring Engaging Ring Bush Bush D.80x90x Roller Cage D.90x98x Roller Cage D.90x98x Reverse Gear 42 T 1 A Reverse Gear 44 T 1 BC Reverse Gear 42 T 1 A Reverse Gear 44 T 1 BC Bearing D.80x130x Bearing D.80x140x36, Oil Tube Oil Tube Washer 1 S.3,00 mm Washer 1 S.2,00 mm Bearing D.49,2x103,1x43, Bearing D.49,2x103,1x43, Constant Gear 37 T 1 A Constant Gear 32 T 1 B Constant Gear 39 T 1 C Constant Gear 32 T 1 B Constant Gear 39 T 1 C Constant Gear 37 T 1 A Constant Gear 32 T 1 B Constant Gear 39 T 1 C Gear 4th Speed 39 T 1 A 023 / A

7 O.E.M. Reference Gear 4th Speed 35 T 1 BC Gear 4th Speed 35 T 1 BC Gear 4th Speed 39 T 1 A Gear 4th Speed 35 T 1 BC Gear 3rd Speed 28 T 1 A Gear 3rd Speed 26 T 1 BC Gear 3rd Speed 26 T 1 BC Gear 3rd Speed 28 T 1 A Gear 3rd Speed 26 T 1 BC Gear 3rd Speed 26 T 1 B Countershaft T 1 A Countershaft T 1 BC Countershaft T 1 A Countershaft T 1 BC Countershaft T 1 B Bearing D.50,8x104,7x39, Bearing D.49,2x103,1x43, Bearing D.49,2x103,1x43, Needle Cage D.45x57x Needle Cage D.45x57x Reverse Gear 20 T 1 A Reverse Gear 22 T 1 BC Reverse Gear 20 T 1 A Reverse Gear 22 T 1 BC Reverse Shaft 1 Old (3) A Reverse Shaft 1 Old (3) BC Reverse Shaft 1 Old (3) A Reverse Shaft 1 Old (3) BC Reverse Shaft 1 Old (3) B Reverse Shaft 1 New Pin 1 New A Pin 1 New BC Pin 1 New A Pin 1 New BC Pin 1 New B CEI Spring Slide Set Oil Seal Kit Gasket Kit Synchro kit 4th/3rd Speed 1 (#) Synchro kit 1st/2nd Speed 1 (@) (1) Only for Input S (2) Only for Input S (3) Old. Replaced by 1 pc. fig pc. fig. 74 (*) New Models only. Do NO MIX Single Cone Synchron. with Double Cone Synchron. (#) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig. 79 (@) Latest Synchro gen. DO NO MIX the two different version. To update the previous one use the synchro rebuilt kit fig / A

8 Suitable To : ZF 7 Gearbox Models 16S151-16S181-16S221-16S251 Planet Carrier (GP) Kit (5 pcs.) Only 16S251 Old New 8 Only 16S Kits Ratios Springs & Slides Kits x 3 x 3 x 3 Kit 6 Only 16S251 x 6 x 6 x 6 Kit x 9 x 9 x 9 Kit Gasket Kit Oil Seal Kit Shifting Forks 4th/3rd 2nd/1st R.G. 16S151 A :13,74-0,84 B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S181 A :- B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S221 A :13,74-0,84 B : 13,80-0,84 C : 16,41-1,00 D :-- E:-- 16S251 A :-- B : 13,80-0,84 C : -- D :-- E: Splitter (GV) Standard Extended Range (GP) Latest Standard 44 45

9 O.E.M. Reference Planetary Carrier Planetary Carrier Planetary Carrier 1 (4) (4) 16S181 Special GP Version. This version use 16S151 GP items. For this version use items marked (4) together Planetary Carrier Planetary Carrier Planet Shaft Planet Shaft Planet Shaft 5 (4) Planet Shaft Planet Shaft Lock Pin D.3x Lock Pin D.5x Spacer Ring Spacer Ring Spacer Ring 10 (4) Spacer Ring Spacer Ring Spacer Ring Spacer Ring 5 (4) Spacer Ring Bush T.14, Roller D.10x16, Planetary Gear Set (5 pcs) Planetary Gear Set (5 pcs) Planetary Gear Set (5 pcs) 1 (4) Planetary Gear Set (5 pcs) Planetary Gear Set (5 pcs) Crown Gear Crown Gear Carrier Hub Carrier Hub Locking Wire Locking Wire Ring Gear Bush Bearing D.104,50x128,40x Saddle Plate Saddle Plate Synchronizer Cone Synchronizer Ring 2 Old Synchronizer Ring 2 New Synchronizer Hub Pressure Piece Inner Spring De.3x Outer Spring De.6x / B

10 O.E.M. Reference Sliding Sleeve Synchronizer Cone (44 Spl.) Synchronizer Cone 59 T (44 Spl) 1 With Retarder Bearing D.90x160x Cover Oil Seal 105x130x Output Flange 1 D H Output Flange 1 D H Output Flange 1 D H Slide 2 Old Slide 2 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork 1 Old Fork 1 New Fork Fork Fork Fork Slide 2 Old Slide 2 New Fork 1 Old Fork 1 New Rod 1 Standard Rod 1 Extended Rod 1 Standard Rod 1 Extended Cap Collar D.25x40x15 1 Standard Cap Collar D.25x38x14,2 1 Extended Piston Cylinder 1 (4) 16S181 Special GP Version. This version use 16S151 GP items. For this version use items marked (4) together. 023 / B

11 O.E.M. Reference Cylinder Bronze Slide Fork Rod Rod Rod Cap Collar D.25x38x14,2 1 Standard Piston 1 Standard Cylinder 1 Standard Cap Collar D.25x40x15 1 Latest Piston 1 Latest Cylinder 1 Latest Spring Slide Set CEI Spring Slide Set Spring Slide Set Oil Seal Kit Gasket Kit 1 (4) 16S181 Special GP Version. This version use 16S151 GP items. For this version use items marked (4) together. 023 / B

INSTRUCTION MANUAL AND PARTS LIST

7360R-2SS INSTRUCTION MANUAL AND PARTS LIST 1. COVER COMPONENTS Ref. No Part No. Name Qty 1 100 1400 Face plate arm 1 2 100 1401 Gasket 1 3 100 1287 Rubber plug (ɸ19) 1 4 100 1288 Rubber plug (ɸ11.8)