1290 751 105a

¨
6 S 850
6 S 890
1290 751 105a
Subject to alterations in design
Copyright by ZF
These repair instructions are protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition: 10.00
1290 751 105a

6 S 850 / 6 S 890 Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instructions for carrying out repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table of springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Speedometer worm or pulse disc and radial sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Speedometer connection piece or pulse sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Reversing lamp switch and pawl stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Removing and installing selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Removing and installing peripheral parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Dismantling and reassembling selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Shift patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3 Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Clutch housing, separate version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Clutch housing, integrated version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Thrust rods, selector clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4 Output bearing and radial sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
5 Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Removing and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Assembling and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7 Main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8 Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Index a: 00-10-01
Contents 6 S 850 / 6 S
890
Page
9 Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Checking wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Version ZF-BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3 Version ZF-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Adjusting shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Main shaft - input shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Index a: 00-10-01
Preface
This manual is intended for skilled personnel who have

been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in

accordance with the state of development on the date
of issue.
However, due to continuing development of the product,

repair work might require work practices and test or
adjustment data which are not contained in this manual.
We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who
have had their practical and theoretical knowledge upda-
ted on a regular basis at our After-Sales Service training
courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out

conscientiously and with care.
Repair work carried out at ZF service points is

guaranteed in accordance with the prevailing
contractual conditions.
Damage resulting from work performed by non-ZF

ZF FRIEDRICHSHAFEN AG personnel in an improper and unprofessional manner,
Division Comm. Vehicle/Special Transmissions together with follow-on costs caused by such work, is
Service Werk 2 excluded from the contractual guarantee agreement.
Tel.: (0 75 41) 77-0 This also applies where genuine ZF spares have not
Fax: (0 75 41) 77-8000 been used.
Index a: 00-10-01 5
Important information
SAFETY NOTICE GENERAL INFORMATION
Companies who repair ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale
and no information about size and weight should be
Personnel required to carry out repairs on ZF products inferred (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
! DANGER agents always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.
CAUTION
The transmission must NOT be hung on the
input shaft NOR on the output flange.
6 Index: 98-01-12
Instructions for carrying out repairs
In any cases of doubt always turn to the the relevant GASKETS, LOCKING PLATES
department within ZF After-Sales Services for
advice. Parts which cannot be removed without being damaged
must always be replaced with new parts (e.g. gaskets
and locking plates).
After removing the transmission from the vehicle clean
thoroughly before opening.
Pay particular attention to the corners and angles of
housings and covers when cleaning. SHAFT SEALS
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower. Always change shaft seals with rough, ripped or
hardened packing washers. Seal contact surfaces must
be totally clean and in perfect condition.
CLEANING PARTS
Remove the old remains of gaskets on all gaskets. REWORKING

Carefully remove burrs or other similar patches of
roughness using a oil-stone Rework may only be carried out on the seal contact
surfaces using plunge-cut grinding, never use an emery
Lube bores and grooves must be free of anti-corrosion cloth. Ensure that there are no traces of grinding traces
agents and foreign matter, check that they can move or rifling from grinding.
without encountering any problems.
If rework is needed on distance washers, shims etc.
Carefully cover opened transmissions to prevent the because of clearance settings, ensure that the reworked
entry of foreign matter.. areas contain no face runout and have the same surface
quality.
REUSING PARTS
TRANSMISSION ASSEMBLY
Parts such as ball or roller bearings, multi-discs, thrust
washers etc., must be inspected by a competent person, Find a clean site to assemble the transmission. Gaskets
who should decide whether or not they can be re-used. are installed without the use of sealing compound or
Replace parts which are damaged or have suffered from grease. When measuring silicon-coated gaskets, take
excessive wear. care not to include the silicon layer in the measure-
ment.
During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.
Index: 98-01-12 7
Instructions for carrying out repairs
BEARINGS d) Duo shaft seals have two packing

washers. The dust-proof packing
If the bearings are filled while hot, these should be washer (X) must face outwards.
warmed up accordingly (e.g. in a heating cabinet). X
The temperature should be approx. 85 °C and may not e) Fill the gap between the packing
exceed 120 °C. All bearings must be coated with trans- washers so it is 60% filled with grease (use a grease
mission oil after assembly. e.g. produced by Aral such as Aralub HL2 or by
DEA such as Spectron FO 20).
f) If possible heat shaft seal bores to between 40 and

50°C (this makes fitting easier). Press the seal shaft
SEALING with mounting or faceplate onto the relevant installa-
tion depth plan.
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing to enter oil ducts RETAINING AGENTS
and bores. On oil-carrying ducts and bores wipe off the
sealing agent on the surfaces to be sealed near apertures Retaining agents* may only be used in places as
to ensure that no sealing agent penetrates the oil feeds specified in the parts list.
when the surfaces are sealed. Always comply with manufacturer’s directions for use
when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAFT SEALS
a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

shaft seals with “steel surround”.
After completing repairs, fill the transmission with
b) Never apply sealing agent to shaft seals with transmission oil. For the procedure and approved oils,
“rubber surround” but apply a thin coat of Vaseline refer to the transmission operating manual and List of
8420 to the outer edge or wet with a lubricant, e.g. a Lubricants TE-ML (refer to identification plate) which
water-soluble, concentrated washing-up liquid (e.g. are available from any ZF After-Sales Service Point.
Pril, Coin, Palmolive). After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
c) Shaft seals with steel and rubber surrounds should be specified torques.
treated on the outer edge of the rubber surround as
described above in section b).
* refer to expendable material
8 Index: 98-01-12
Tightening torques
Tightening torques for nuts and bolts, extract from

ZFN 148
This standard applies to bolts acc. to DIN 912, DIN 931, Surface condition of bolts: thermally blackened and
DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. oiled or galvanized and oiled or galvanized, chrome-
This Standard contains data on tightening torques (MA) plated and oiled.
for bolts in strength categories 8.8, 10.9 and 12.9 and
nuts in strength categories 8, 10 and 12. Tighten screws with a calibrated torque spanner.
NOTE
Irregular tightening torques are listed separately in the
Repair Manual.
Regular thread Fine screw thread
Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 5 5,5 8,1 9,5 M 9x1 36 53 62
M 6 9,5 14 16,5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1,25 49 72 84
M 8 23 34 40 M 12 x 1,25 87 125 150
M 10 46 68 79 M 12 x 1,5 83 122 145
M 12 79 115 135 M 14 x 1,5 135 200 235

M 14 125 185 215 M 16 x 1,5 205 300 360
M 16 195 280 330 M 18 x 1,5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1,5 430 620 720
M 22 530 750 880 M 22 x 1,5 580 820 960
M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
Edition: August 1991 / checked 1997
Index: 98-01-12 9
Tightening torques
Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643
The screw plug tightening torques MA were determined The tightening torques MA were determined for
according to DIN 7604, for screwing into steel, grey screwing into steel, grey cast and aluminium alloys.
cast, and aluminium alloys. The values are based on experience and are inten-
The values are based on experience, and are ded as reference values for the designer.
intended as reference values for the designer.
The values for the tightening torque MA shall also be General rule: screw/bolt class 5, ZFN 148-1
used for screw plugs according to DIN 908 and Material 9SMnPb28K acc. to DIN 1651
DIN 910, as the thread geometries are almost identical. Surface conditions: as manufactured
General rule: Screw/bolt class 5, ZFN 148-1 (without surface protection) and lightly
Screw/bolt material: steel acc. to oiled or galvanized, chromated and
DIN 7604. Surface condition: as manu- lightly oiled
factured (without surface protection) and
lightly oiled or galvanized, chromated
and lightly oiled
Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)
Dimensions Tightening torque Pipe Thread Tightening-

screwed into outer torque MA
steel/grey cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 30
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 40
M 22 x 1.5 60 / 80* 50 / 65*
M 24 x 1.5 70 60 12 M 16 x 1.5 45
M 26 x 1.5 80 / 105* 70 / 90*
M 27 x 2 80 70 15 M 18 x 1.5 50
M 30 x 1.5 100 / 130* 90 / 130*
M 30 x 2 95 85 18 M 22 x 1.5 60
M 33 x 2 120 110
M 36 x 1.5 130 115 22 M 26 x 1.5 90
M 38 x 1.5 140 120
M 42 x 1.5 150 130 28 M 30 x 1.5 130
M 42 x 2 145 125
M 45 x 1.5 160 140 35 M 38 x 1.5 140
M 45 x 2 150 130
M 48 x 1.5 170 145
M 48 x 2 160 135
M 52 x 1.5 180 150
M 60 x 2 195 165
M 64 x 2 205 175
* DIN 7604 Form C
Status October 1995
10
6 S 850 Consumables
Description Name Approx. Application Remarks

ZF reference no. quantity
Sealing compound
0666 790 017 Wevo-L100 Screw plugs trans.-housing
Hinged bolts trans.-housing
Grease
0671 190 016 Vaseline 8420 Roller cage main shaft
Grease for example:

0750 199 001 Spectron FO 20 Bearing bush selector
11
Adjustment data 6 S 850 / 6 S 890
Description Dimension Measurement device Remarks
01. Axial clearance of bearing 0 mm Depth gauge Clearance given, check

on input side
02. Axial clearance of bearing 0 ÷ 0.10 mm Feeler gauge Adjustment with circlips of
on output side various thicknesses
03. Axial clearance of circlips Feeler gauge Adjustment with circlips of

on synchro bodies various thicknesses
5th/6th gear, 0 ÷ 0.05 mm
3rd/4th and 1st/2nd gear 0 ÷ 0.10 mm
04. Axial clearance of helical 0.25 ÷ 0.65 mm Feeler gauge Clearance given, check
gear 6th gear on main
shaft (overdrive-version)
5th gear on main shaft
(through-drive version)
gear 4th gear main shaft
gear 3rd gear main shaft
gear 2nd gear main shaft
08. Axial clearance of spur 0.15 ÷ 0.50 mm Feeler gauge Clearance given, check
gear 1st gear main shaft
09. Axial clearance of reverse 0.3 ÷ 1.3 mm Feeler gauge Clearance given, check
idler gear on reverse shaft
10. Axial clearance of layshaft 0 ÷ 0.1 mm Depth gauge Bring bearing to abutment
(without clearance) and
measure. Adjust with shims
(2)
11. Axial clearance of circlip 0 ÷ 0.05 mm Feeler gauge Adjustment with circlips of
on layshaft input end various thicknesses
12. Clearance of fulcrum pads 0.4 ÷ 0.7 mm Feeler gauge Larger clearance denotes
in guide grooves or sliding wear on fulcrum pads or
sleeves (new condition) sliding sleeve
12
6 S 850 / 6 S 890 Adjustment data
13. Max. possible clearance of approx. 1.2 mm Feeler gauge If value is exceeded, deter-
fulcrum pads in sliding mine amount of wear and
sleeve or guide grooves exchange respective part(s)
(visual test)
14. Clearance of selector fork 0.2 ÷ 0.5 mm Feeler gauge Larger clearance denotes
in guide grooves. Reverse wear on shifting fork or
gear (new condition) guide grooves
15. Max. permissible approx. 1 mm Feeler gauge If value is exceeded deter-

clearance of shifting fork mine amount of wear and
in guide grooves reverse exchange respective part or
gear parts (visual test)
16. Axial clearance of speedo- > 0.1 mm Depth gauge Value given, check by hand
meter shaft (perceptible)
17. Backlash of speedometer 0.1 ÷ 0.2 mm Value given, check by hand

pinion (perceptible)
18. Wear limit of synchonizer Feeler gauge If measurement is below

rings or clutch body, specified value, exchange
ZF-BK 0.8 mm synchronizer rings or
ZF-D 1.5 mm possibly clutch body
19. For information: 0.6 mm Feeler gauge Upper limit of synchronizer

Synchronizer clearance clearance is given by wear
1st - 5th gear (axial) limit of 0.8 mm
20. For information: 270 ÷ 310 N All compression springs in

Synchronizer pressure of synchronizers must be
three sliding sleeves in of replaced by new ones; this
synchronizer system will guarantee specified
synchronizer pressure
21. Distance from housing 7 mm (Depth gauge) (Measure installation size

edge to face of shaft seal Adapter 1X56 137 133 from cast edge to sealing
on output end ring). The installation size is
obtained when using the
adapter
13
Adjustment data 6 S 850 / 6 S 890
22. Temperature for shrink fit 120 °C Temperature Ensure axial abutment
of thrust bushing for measuring probe or
helical gear 4th gear thermometer
23. Temperature for shrink fit 120 °C Temperature Ensure axial abutment
of thrust bushing for spur measuring probe or
gear. Reverse gear on thermometer
main shaft
24. Temperature for pushing 100 ÷ 120 °C Temperature Use lube oil on sealing ring
on input flange measuring probe or race
thermometer
25. Temperature for shrink fit 160 ÷ 180 °C Temperature Mating surfaces of gears and
of layshaft gears measuring probe or shaft must be free of oil and
thermometer grease
26. Tightening torque for hex Ø120 mm = 120 Nm Torque wrench Coat hex bolt and thrust
bolt on output flange Ø150 mm = 140 Nm washer with sealing
compound
27. Tightening torque of 160 Nm Torque wrench Fit spring washers, coat
hinged bolts thread with sealing
M 18 x 1.5 in housing compound
28. Tightening torque for 100 Nm Torque wrench Fit sealing ring
speedo connection
M 30 x 1.5
29. Tightening torque of 23 Nm Torque wrench Attach washer

M6x30 hex bolts on
release device
30. Tightening torque of 78 Nm Torque wrench

tubular neck on release
device
31. Tightening torque of vent 10 Nm Torque wrench

of tubular neck
32. Tightening torque for 10 Nm Torque wrench Do not exceed specified

breather M 10 x 1 value
14 Index a: 00-10-01
6 S 850 / 6 S 890 Adjustment data
33. Tightening torque for 50 Nm Torque wrench Fit sealing ring. Do not use
screw plug M 24 x 1.5 tapered screw plugs
(oil filler and oil control
plugs) in housing
34. Tightening torque for 50 Nm Torque wrench Fit sealing ring

screw plug M 24 x 1.5 of
detent element on selector
housing
35. Screw plug (tapered) 50 Nm Torque wrench Coat screw plugs with
tightening torque sealing compound. Do not
M 24 x 1.5 (oil fill, oil use screw plugs with collar
overflow and oil drain
screw plugs) in housing
36. Tightening torque for 45 Nm Torque wrench Fit spacer ring

reversing light switch
M 18 x 1.5
37. Tightening torque for neu- 50 Nm Torque wrench Fit sealing ring
tral position switch
M 18 x 1.5
38. Tightening torque for pawl 65 Nm Torque wrench Coat pawl stop thread with
stop M 16 x 1.5 in selector sealing compound. Secure
and gearbox housings with locking plate
39. Tightening torque for 35 Nm Torque wrench Coat with sealing compound
screw plugs (tapered)
M 18 x 1.5 in housing
40. Tightening torque of 45 Nm Torque wrench

pulse sensor on housing
Index a: 00-10-01 15
Table of springs 6 S 850 / 6 S 890
Part number Installation point No. of Wire diam. Spring diam. Untensioned
windings in mm in mm length in mm
0732 040 410 Synchronizers/ZF-D 16.5 1.10 5.90 26.1

Main shaft
0732 040 904 Selector mechanism 7.5 1.80 26.1 50.5

on reverse gear pawl
0732 042 510 Synchronizers/ZF-BK 12.5 1.00 4.8 22.7

Input shaft and main shaft
16 Index a: 00-10-01
6 S 850 / 6 S 890 Special tools
Fig. Special tools Order no. Application Qty. Remarks

no.
1X56 099 070 Chapter

4.2
Adapter
1 for radial sealing ring (42 x 62) 1
on output

1.4
Adapter
2 with conical extension for radial 1
sealing ring in speedo connecting
piece

2.2
Adapter
3 for radial sealing ring (25 x 35 x 7) 1
and scraper (25 x 35 x 7 x 10)
of selector

8
Tool
4 used in conjunction with gripping 1
device 1X56 136 724 and
1X56 136 725 for tapered roller
bearings on layshaft

8
Gripping device
5 used in conjunction with tool 1
bearing on layshaft mounted on
input side
17
Special tools 6 S 850 / 6 S 890

no.

8
Gripping device
6 used in conjunction with tool 1
bearing on layshaft mounted on
output side

1.2
Adapter
7 for radial sealing ring (60 x 74) 1
on output

2.2
Protective sleeve
8 used in conjunction with adaptor 1
1X56 119 916 for radial sealing ring
and scraper of selector

2.3
Adapter
9 for bearing bush on selector 1

4.4
Lifting device
10 for mainshaft and layshaft 1
18
6 S 850 / 6 S 890 Special tools

no.

4.5
Protection ring
11 for heating output bearing’s inner 1
race

4.5
Guide strip
12 for fixing shaft package and slector 1
rails, used in conjunction with
1X56 137 236
1X56 137 450
Assembly support
13 together with 1
adapter 1X56 136 998
1X56 138 186
Angle adapter
14 for complete transmission 1
together with 1X56 137 450 and
1X56 136 998
1X56 136 998
Adapter
15 together with assembly support 1
1X56 137 450
Index a: 00-10-01 19
20
Special tools
1X56 138 190 1X56 137 135 1X56 119 916 1X56 137 134
1X56 137 136 1X56 137 133
Index a: 00-10-01
1X56 099 070
013167
1X56 100 632

6 S 850 / 6 S 890
1X56 136 724 1X56 122 304 1X56 138 187 1X56 136 725
6 S 850 / 6 S 890 Output
1 Output
1.1 Output flange

1
Removal
01 Undo hex bolt (3) and remove together with thrust
washer (2).
02 Prevent output flange (1) from turning with
commercial flange holder.
03 Remove output flange (1) with commercial two or
three-arm puller. 2 3
Installation
01 Speedometer worm and radial sealing ring in acc.
with Section 1.2.
017202
! DANGER
Ensure protective gloves are used when handling
heated output flange.
02 Heat output flange (1) to max. 120° C.

03 Coat sealing ring friction surface of flange with
lubricating oil and slide flange onto main shaft.
04 Prevent flange from turning with commercial
flange holder.
05 Coat the mating face of thrust washer (2) with
WEVO-L100 sealing compound and place the
washer onto the output flange.
06 Coat the contact face on the head of hex bolt (3)
with WEVO-L100 sealing compound.
07 Insert and tighten hex bolt (3).
Tightening torque:
output flange Ø120 mm = 120 Nm
output flange Ø150 mm = 150 Nm.
Index a: 00-10-01 1-1

Output 6 S 850 / 6 S 890
1.2 Speedometer worm, pulse disk and radial sea-

ling ring 3
54
Removal
01 Remove radial sealing ring (3).
02 Take speedometer worm (5) or pulse disk (8) off
the main shaft.
8
017203
Installation
01 Slide on speedometer worm (5) or pulse disk (8).
02 Insert radial sealing ring (3) with adapter
1X56 137 133 as follows and grease sealing lip.
NOTE
a) Apply a thin coat of sealing compound to outer
diameter of radial sealing ring with steel coat.
1
b) Moisten outer diameter of radial sealing ring
with rubber coat using a lubricant such as
water-soluble liquid dishwashing detergent
(e.g. Fairy Liquid). 2
7mm
03 Fit output flange in acc. with Section 1.1. 3
4
5 8
1 = Adapter 1X56 137 133
2 = Main shaft
6
3 = Radial sealing ring
4 = Housing 7
5 = Speedometer worm
6 = Output bearing 017205
7 = Circlip
8 = pulse disk
1-2 Index a: 00-10-01

6 S 850 / 6 S 890 Output
1.3 Speedometer connection piece or pulse sensor

3
Removal
4
01 Unscrew tacho connection piece (1) or pulse sen-
sor (4) depending on version. 1
NOTE
Do not dismantle further as this is complete unit.
Installation
01 If radial sealing ring (3) in speedometer connec-
tion piece (1) is defective, replace if possible or
insert new radial sealing ring on top of defective
one. Installation tool 1X56 100 632.
02 Screw in speedometer connection piece with
sealing ring (2) and tighten.
Tightening torque = 100 Nm. 017205
03 Perform manual check of speedometer pinion for

existing axial play > 0.1 mm and backlash 0.1 to
0.2 mm.
04 Screw in and tighten pulse sensor (4) depending
on version.
Tightening torque = 45 Nm.
Index a: 00-10-01 1-3

Output 6 S 850 / 6 S 890
1.4 Reversing lamp switch and pawl stop

1
Removal
01 Unscrew reversing lamp switch (4) and pawl stop 2
(1) for reverse gear.
NOTE
Some spec lists may include a pawl stop combined
3 4
with a reversing lamp switch.
017206
Installation
01 Installation note Tightening torque Remarks
Pawl stop (1) 65 Nm Coat thread with sealing compound.

Fit washer (2).
Reversing lamp switch (4) 48 Nm Fit washer (3).
1-4
6 S 850 / 6 S 890 Shift mechanism
2 Shift mechanism
2.1 Removing and installing selector 1
Removal
01 Unscrew hex bolts (1) of selector and remove
selector (2) with gasket (3). 2
Fig. 013192 = torque shaft right

Fig. 013193 = torque shaft left
003 176
013192
Installation
01 Set thrust rods in gear and drivers of selector to
neutral position.
02 Fit new gasket (3) to installation face for selector.
03 Mount selector (2). Fit hex bolts (1) with spring
washers and tighten.
NOTE
The shift turret housing must be centered on the
transmission housing so that the play (excess shift
travel) is the same on each side.
013193
2-1
Shift mechanism 6 S 850 / 6 S 890
4
2 3
1
7 6
013117
2.2 Removing and installing peripheral parts
Dismantling 1 = Detent 1st - 6th speed

2 = Breather
NOTE
3 = Pawl stop, gate reverse
The operations described below apply by to all
4 = Neutral position switch
types of selector.
5 = Sealing plug
01 Mark position of selector lever relative to rotary 6 = Gear shift lever
selector mechanism and remove selector lever and 7 = Protecting cap
protective cap.
02 Remove detent, breather, pawl stop and, if fitted,
neutral positon switch or sealing plug.
2-2
Assembly
01 Installation note Tightening torque Remarks
Pawl stop 65 Nm Coat thread with sealing compound.

Fit tab washer and secure.
Neutral position switch 50 Nm Fit sealing ring
Detent 1st - 6th speed 50 Nm Fit sealing ring
Breather 10 Nm
1 2 3 4 5 6 7
013118
02 For RH drive version, coat inside of gearshift tube 05 Slide on protective cap and fit selector lever
(2) with grease e.g. ARALUB HL2 before bearing (dismantling mark).
bush (3) is installed. Tightening torque of hex nut = 49 Nm.
03 Fit protective sleeve 1X56 137 134 (6) to selector
output.
1 = Rotary selector mechanism
04 First drive in radial sealing ring (4) and then 2 = Gearshift tube
scraper ring (5) using adapter 1X56 119 916 (7) 3 = Bearing bush
as follows and grease sealing lips: 4 = Radial sealing ring
5 = Scraper ring
NOTE
6 = Protective sleeve 1X56 137 134
a) Apply a thin coat of sealing compound to outer
7 = Adapter 1X56 119 916
diameter of radial sealing rings with steel coat.
b) Moisten outer diameter of radial sealing rings
with rubber coat with a lubricant such as water-
soluble liquid dishwashing detergent (e.g Fairy
Liquid).
2-3
2.3 Dismantling and reassembling selector
Removal
01 Drive two pairs of roll pins each out of selector
finger and rotary selector mechanism by
positioning selector mechanism in such a way that
the roll pins point into the recess (removal path Fig.
003180) in the selector housing.
Left hand selector output version (Fig. 01707)

02 Release circlip (13) opposite selector output.
03 Move rotary selector mechanism (4) toward
selector output and knock out cover (12) and/or
bush (11) or (17).
If fitted with spring "Q3" only

04 Remove compression spring (16) and washer (15).
Remove snap ring (14).
If fitted with springs "Q1" and "Q3"

05 Release circlip (10) from rotary selector
mechanism.
06 Collect bush (9), compression spring (8) and
washer (7).
07 Pull out rotary selector toward selector output and 003 180
remove selector finger (6) with locking piece (5).

003180
08 Remove scraper ring (1) and radial sealing ring (2).
Right hand selector output version (Fig. 017208)

09 Remove cover (12) and.gasket (11).
10 Remove V-ring or circlip (13).
11 Move rotary selector (4) toward selector output and
remove sleeve (10), compression spring (9), washer
(8) and intermediate tube (7).
12 Pull out rotary selector fully and remove selector
finger (6) with locking piece (5).
13 Remove scraper ring (1) and radial sealing ring (2).
14 Remove bearing bushes (21 and 22) (Fig. 013122)
if necessary using suitable drift.
2-4 Index a: 00-10-01

6 S 850 / 6 S 890 Left hand shift mechanism
13
12
11
10
9
8
7
Shift pattern II
Q1
Q3
13
18
17
3
16
15
14
10
9
8
7 4
2
Q8 1
5 6
13
12
11
10
19
Shift pattern I 9
017207
1 = scraper ring 8 = spring(s) 15 = washer

2 = radial sealing ring 9 = bush 16 = spring
3 = selector housing 10 = circlip 17 = bush
4 = rotary selector 11 = bush 18 = O-ring
5 = locking piece 12 = cover 19 = washer
6 = selector finger 13 = circlip
7 = washer 14 = snap ring
Index a: 00-10-01 2-5

Right hand shift mechanism 6 S 850 / 6 S 890
1
2
Q4
4 Shift pattern II
7
8
9
10
13
11
5 6 12
14
Q9
4
Shift pattern I
7
8
9
10
13
11
12
14
017208
1 = scraper ring 7 = intermediate tube 13 = V-ring or circlip

2 = radial sealing ring 8 = washer 14 = hex bolt
3 = selector housing 9 = spring(s)
4 = rotary selector 10 = bush
5 = locking piece 11 = gasket
6 = selector finger 12 = cover
2-6 Index a: 00-10-01

Installation
01 First fit a bearing bush (2 or 3) (Fig. 013122) into
long neck, then second bearing bush into short 6 20
5 4
neck using adapter 1X56 137 135.
02 Place selector finger with locking piece in
installation position (see Fig. 017207 and 017208)
and push in rotary selector mechanism. The detent
of the rotary selector points towards the threaded
bore for pawl stop. Align holes for roll pins in
selector finger and rotary selector mechanism.
Drive in two pairs of roll pins each (see Fig.
003180).
03 Install the springs fitted in the reverse order to that
described under „Removal“. Fit cover (12, Fig.
017207) with sealing compound. 013121
04 With selector output to the right, fit cover with

new gasket.
05 Check the play on pin (20) by moving selector 13
finger (6). Permitted travel at selector finger:
2mm
0.05 to 0.40 mm. 221
3 = Selector housing
21 = Bearing bush
22 = Bearing bush
322
013122
Index a: 00-10-01 2-7

2.4 Shift patterns

shift mechanism left, right or standing Q1
2.4.1 Transmission horizontal
Horizontal torque shaft left / Shift pattern II
Spring pack arrangements Q1 and Q3
013123
Q3
013124
Transmission horizontal
Horizontal torque shaft left / Shift pattern I Q6
017216
Q8
017217
2-8 Index a: 00-10-01

6 S 850 / 6 S 890 Schaltgehäuse
2.4.2 Transmission horizontal

Horizontal torque shaft right / Shift pattern II Q2
013125
Q4
013126
Transmission horizontal
Horizontal torque shaft right / Shift pattern I Q7
017218
Q9
017219
Index a: 00-10-01 2-9

2.4.3 Transmission vertical (upright)

Vertical torque shaft Q5
Spring pack arrangement Q5
013127
2-10
6 S 850 Reverse gear
3 Reverse gear
Removal 1
01 Unscrew hex bolt (1), remove washer (2).
2
02 Unscrew hex bolts (6), remove sealing cover (5)
and gasket (4).
03 Drive out reverse bolt (9) toward output using
drift (8).
NOTE
The connection housing or integrated clutch hou-
sing must be removed (see section 4.3).
04 Remove reverse gear (10) with needle cages (11).
Installation
01 Insert O-ring (12) in annular groove of reverse
bolt (9). 4
02 Set reverse gear (10) with needle cages (11) to

installation position. 5
03 Heat the housing to approx. 85°C in the area
around the hole for the reverse bolt.
04 Drive in reverse bolt until the lower edge of the 6
circular groove is level with the recess of the
013128
threaded bore.
05 Check axial play of reverse gear. It must be
0.3 ÷ 1.3 mm. 8
06 Insert washer (2) into the circular groove in the
15
reverse bolt. Screw in hex bolt (1) and tighten.
07 Fit sealing cover (5) with new gasket (4).
08 Screw in hex bolts (6) and tighten. 11
10
11
13 = Layshaft
14 = Tapered roller bearing
15 = Transmission housing 12
9 14 13
013129
Index a: 00-10-01 3-1

6 S 850 / 6 S 890 Input
4 Input
9
4.1 Clutch housing, separate version 4 7
4.1.1 Separate clutch housing
Removal
01 Loosen wires or cable clip (1). Take off clutch
lever (2).
02 Undo hex bolts (3) and remove them together with
their washers. Take clutch housing (4) off the
transmission.
03 Remove clutch release cylinder (5) or plate (6), 3
as necessary.
04 Remove cover (7), as necessary.
05 Undo ball pin (8) and remove it together with hex
nut (9) and washer, as necessary.
Installation 8
01 Insert ball pin (8) and tighten hex nut (9) with
washer, as necessary.
Initial tightening torque (pre-assembly) = 15 Nm,
Final tightening torque (final assembly) = 195 Nm.
02 Screw on cover (7), as necessary.
03 Screw on clutch release cylinder (5) or plate (6),
as necessary.
Tightening torque = 23 Nm. 1 5
04 Fit clutch housing (4) onto the transmission using

the connection plate. 6
05 Insert hex bolts (3) with the washers fitted and

tighten them.
06 Insert clutch lever (2) and secure it using wire or
013130
cable clip (1).
Index a: 00-10-01 4-1

Input 6 S 850 / 6 S 890
4.1.2 Connection plate
Removal
01 Undo hex bolts (1) and take off connection plate
(2) together with gasket (3).
02 Take off shims (4) which come free. 4
03 Remove radial sealing ring (5) from the

connection plate.
Installation
01 Grease the sealing lip on the new radial sealing
ring and use drift 1X56 099 070 to insert the new
seal in connection plate (2).
NOTE
a) Lightly coat the outer edge of the radial sealing
ring with sealing compound if it has a steel 3
surround.
b) Coat the outer edge of the radial sealing ring 2
with a water-soluble washing liquid (e.g. Pril or
similar) if it has a rubber surround.
02 Check the play between the input shaft and the
connection plate, see section 10.3. 1
5
03 Fit a new metal gasket (3).
NOTE
Make sure the bead is facing the connection plate 013131
(see fig. 010136).
NOTE
Shims (4) must be selected and fitted as described
in section 10.2. Connection plate
04 Carefully slide the connection plate over the input

shaft and fit it onto the housing.
05 Insert hex bolts (1) with their washers fitted and
tighten them. Gasket
Tightening torque = 23 Nm. Transmission
010136
4-2
6 S 850 / 6 S 890 Input
4.2 Clutch housing, integrated version

4.2.1 Release device
Removal
01 Unfasten tubular necks (1 and 2) and remove.
02 Unfasten hex bolts (3) and take off with washers.
03 Fully remove release device (4).
NOTE
Do not dismantle release device further; it is a
complete apart.
Fitting
01 Insert release device (4) in clutch housing.
02 Screw in hex bolts (3) with washers and tighten.
03 Screw in tubular necks (1 and 2) and tighten.
3
3
1
017209
Index a: 00-10-01 4-3

Input 6 S 850 / 6 S 890
4.2.2 Connection plate

Removal
01 Unfasten hex bolts (1) and remove with washers.
02 Use pry bar to carefully unfasten connection plate
(2) and take off gasket (3).
03 Remove adjustment washers (4) coming loose
4
from countershaft.
04 Remove shaft seal (5) from connection plate.
Fitting
01 Grease sealing lip on new shaft seal (5) and use
tool 1X56 099 070 to insert in connection plate
(2).
NOTE
a) Lightly coat the outer edge of the radial sealing
ring with sealing compound if it has a steel
surround.
b) Coat the outer edge of the radial sealing ring 3
with a water-soluble washing liquid (e.g. Pril or
similar) if it has a rubber surround. 2
NOTE
Adjustment washers (4) are measured and fitted in
Section 10.2.
03 Fit new gasket (3). 5
1
04 Carefully guide connection plate (2) over the input
shaft and fit on housing.
05 Screw in hex bolts (1) with spring washers and 017215
tighten.
4-4 Index a: 00-10-01

6 S 850 / 6 S 890 Input
4.3 Connection housing or integrated clutch

housing
1
Removal
01 Unscrew hex bolts (1) around circumference of
connection housing or clutch housing.
02 Drive out half-way both fixing pins (2).
03 Lift off connection housing or clutch housing
parallel from joint face.
04 Take off gasket (3). 2
05 Slide roller cage (4) off main shaft.
NOTE
If the connection housing or clutch housing can-
not be removed, the clutch body on the input shaft
is twisted. Should this occur, proceed as follows:
Repeatably turn input shaft until clutch body
becomes loose.
003 188
06 Only for separate version: 2

Measure and note down distance “B”, see section 3 4
10.1.
003188
Installation
01 Slide roller cage (4) onto main shaft.
02 Using two guide pins, fit new gasket (3) to
transmission housing.
03 Install input shaft in connection housing or clutch
housing in acc. with Section 6.
04 Mount connection housing or clutch housing with
input shaft in parallel with transmission housing.
05 Screw in hex bolts (1) with spring washers around
circumference of connection housing or clutch
housing and tighten.
06 Drive both fixing pins (2) into installation
position.
Index a: 00-10-01 4-5

Input 6 S 850 / 6 S 890
4.4 Shiftmechanism, mainshaft and layshaft
Removal
01 Position transmission housing vertically and fit
lifting device 1X56 137 136 (1) and attach guide
1
strip 1X56 138 190 (2). 2
02 Fix and secure shaft package and slector rails.
7
03 Insert auxiliary strip (3) (to be produced in-house
- 60x20x20 mm) in selector gate. 6
CAUTION 3
5
Reverse gear must be removed in acc. with Section 3.
03 Unscrew 3 articulated bolts (4) from each side of 8
the transmission housing. 4
04 Fit commercial two-arm puller to the output end.
Press the shafts towards the input end so they 4
come out of the output bearing.
05 Lift main shaft and layshaft together out of
transmission housing using lifting device
1X56 137 136.
4
06 Remove gearshift forks in the following order:
complete gearshift forks for 5th/6th gear (5),
complete gearshift forks for 3rd/4th gear (6),
complete gearshift forks for 1st/2nd gear (7).
07 Unfasten guide strip.
017214
08 Remove selector rails for R gear (8) with selector

fork for R gear (9) and thrust rods.
09 Remove auxiliary strip, take off thrust rods for
5th/6th gear (10) and for 3rd/4th gear (11).
10 Take thrust rod for 1st/2nd gear (12) off selector
rails.
11 Dismantle shaft package.
4-6 Index a: 00-10-01

6 S 850 / 6 S 890 Input
5a
4
7
6
4
4 4
9
12
4 11
10
8
013133
Installation 06 Insert R gear selector rails and selector fork in

mainshaft. Engage gearshift forks and thrust rods.
01 Insert thrust rod for 1st/2nd gear (12) in R gear
selector rail (8). 07 Use guide strip 1X56 138 190 to secure selector
rail.
02 Insert both thrust rods for 3rd/4th gear (11) and
thrust rod for 5th/6th gear (10) between thrust rod 08 Insert gearshift forks for 3rd/4th gear (6) and
for 1st/2nd gear and R gear selector rail and fix fulcrum pads in sliding sleeve and mesh with
with auxiliary strip. thrust rod for 3rd/4th gear (11).
03 Roll complete mainshaft and countershaft away 09 Insert gearshift forks for 5th/6th gear (5) and
from one another on the workbench and mesh fulcrum pads in sliding sleeve and mesh with
gears. thrust rod for 5th/6th gear (10).
04 Fit lifting fixture 1X56 137 136 and place guide NOTE
strip 1X56 138 190 on lifting fixture. Raise shafts. Gearshift fork (5): overdrive
Gearshift fork (5a): direct drive
05 Insert gearshift forks for 1st/2nd gear (7) and
fulcrum pads into sliding sleeve and place on 1st
gear of attachment.
Index a: 00-10-01 4-7

Input 6 S 850 / 6 S 890
Installation
01 Heat the output bearing's inner race to max.

110 °C. Place protection ring 1X56 138 187 (1)
onto the output bearing to do this.
1
NOTE
The shafts must be assembled correctly ready for
installation.
! DANGER
Only touch heated protective tool when wearing pro-
tective gloves. 013194
02 Remove protection ring 1X56 138 187 and

carefully insert the shafts fully into the transmissi-
on housing.
03 Pull the shafts into the correct axial position from
the output end using a bushing (against the
bearing inner race or speedometer worm) and a
hex bolt (M12x1.5).
NOTE
Separate clutch housing version
Check the installation is correct by measuring
distance "B", see section 10.1. Remove the
bushing and hex bolt. 5
04 Remove fixtures and auxiliary strip

4
05 Coat thread of articulated bolts with sealing com-
pound. First screw in articulated bolts of 1st/2nd
gear with spring washer. 3
NOTE
Articulated bolts for 1st/2nd gear (2) = approx
48.5 mm
Articulated bolts for 3rd/4th gear (3) = approx 2
55.0 mm
Articulated bolts for 5th/6th gear (4) = approx
55.0 mm
NOTE
Overdrive version (4), 017307
direct drive version (5).

06 Screw in and tighten the remaining articulated
bolts and spring washers as previously described.
4-8 Index a: 00-10-01

6 S 850 / 6 S 890 Output
4.5 Output bearing, radial sealing ring
Removal 2 3 4
01 Remove radial sealing ring (5) from transmission

housing (1).
02 Release circlip (3).
03 Drive out roller bearing (4) and taper roller
bearing outer race (2) without twisting. 1
5
Installation
013135
01 To insert the bearing outer race (2), it is of

advantage to heat the transmission housing (1)
around the bearing bore to approx. 60 °C.
02 Insert bearing outer race (2), drive on under press
until it is abut with no play (see arrow).
03 Insert ball bearing (4) into the transmission
housing and use a press to push it into position
(see arrow).
04 Insert circlip (3) with 0 ÷ 0.1 mm clearance.
05 Install radial sealing ring (5) as described in
Section 1.2.
4-9
6 S 850 / 6 S 890 Transmission housing
017210
5 Transmission housing
Removal Installation
01 Undo hex bolts (1) and remove cover (2) together 01 Coat the screw plugs with WEVO-L100 sealing
with the gasket, as necessary. compound and insert them.
Tightening torque M24x1.5 = 50 Nm.
NOTE
Tightening torque M18x1.5 = 35 Nm.
Side cover (2) is not fitted on all versions.
02 Fit cover (4) onto the housing together with a new
02 Undo hex bolts (3) and remove cover (4) together
gasket. Insert and tighten hex bolts (3).
with the gasket, as necessary.
03 Undo and remove the screw plugs, as necessary.
03 Fit cover (2) onto the housing together with a new
04 Remove the type plate if the housing is to be gasket. Insert and tighten hex bolts (1).
changed. Tightening torque = 46 Nm.
Index a: 00-10-01 5-1

6 S 850 / 6 S 890 Input shaft
6 Input shaft
Removing and dismantling

01 Press out input shaft (1) from connection housing
(2) or clutch housing (7) in its entirety.
02 Remove bearing outer race (3) from the
connection housing or clutch housing.
03 Detach circlip (4).
04 Only pull off ball bearing (5) from the input shaft
if it is worn.
05 Take off washer (6).
Assembling and installing

01 Fit washer (6) onto the input shaft. 7
2
! DANGER
Ensure protective gloves are worn when handling
heated ball bearings.
02 Heat ball bearing (5) to approx. 85°C and press it 3

onto input shaft (1).
NOTE
Ensure that the fitting collar is facing towards the
transmission. There must be no axial play between
the bearing and the input shaft.
03 Attach circlip (4).
04 Heat up the bearing bores on the connection
housing (2) or clutch housing (7) to approx. 60°C
before fitting bearing outer race (3) and the input
shaft.
05 Insert the assembled input shaft in the correct
axial position.
1
06 Fit outer race (3) of the taper roller bearing,
ensuring it is flush.
6
5
017211
Index a: 00-10-01 6-1

6 S 850 / 6 S 890 Main shaft
7 Main shaft
Dismantling
NOTE
Dismantle the shaft using a press or a 2- or 3-arm
puller.
01 Grasp reverse gear wheel (1) and pull it off
together with thrust bush (2).
15
02 Remove needle cage (3) from the main shaft. 16
03 Grasp 1st speed helical gear (4) and pull it off 17
together with clutch body (5). 18
19 14
04 Remove needle cage (6) and detach circlip (7). 13
05 Take off clutch disc (8), inner ring (9), 20
intermediate ring (10) and outer ring (11).
06 Pull off sliding sleeve (12), making sure you catch
the pressure pieces and compression springs
which come free (e.g. using a cloth).
07 Remove coupling elements (13). 8
08 Grasp 2nd speed helical gear (19) and pull it off 9
together with clutch disc (18), inner ring (17), 10
intermediate ring (16), outer ring (15) and
11
synchronizer hub (14). 12
09 Take off needle cage (20).
3
2
1
5
4
6
7
013138
7-1
Main shaft 6 S 850 / 6 S 890
10 Detach and remove circlip (21).

27
11 Take off clutch body (22) and synchronizer ring 26
(23). 24
12 Pull off sliding sleeve (24), making sure you catch

the pressure pieces and compression springs 23 25
which come free (e.g. using a cloth). 22
21
13 Grasp clutch body (27) and pull it off together 44
with synchronizer ring (26) and synchronizer hub 43
(25).
14 Take off 6th speed helical gear (28) together with 32
needle cage (29).
33
15 Detach and remove circlip (30). 31
30
16 Take off thrust washer (31), 4th speed helical gear
(32) and needle cage (33). 29
28
17 Detach and remove circlip (34).
18 Take off clutch body (35) and synchronizer ring
(36). 40
19 Pull off sliding sleeve (37), making sure you catch 39
the pressure pieces and compression springs
which come free (e.g. using a cloth). 37
20 Grasp 3rd speed helical gear (41) and pull it off 38

together with clutch body (40), synchronizer ring 34
(39) and synchronizer hub (38). 36
35
21 Take off needle cage (42).
22 Detach circlip (43) and remove it together with
inner ring (44), as necessary.
42
41
013155
7-2
6 S 850 / 6 S 890 Main shaft
Assembly
19
! DANGER
heated parts. 20
01 Lightly oil needle cage (20) and slide it onto the

main shaft together with 2nd speed helical gear
(19). Make sure the engaging teeth for the clutch
body are facing towards the output end.
02 Check that the synchronizer parts have not
reached their wear limit (see section 9).
03 Place clutch disc (18) onto the engaging teeth of
helical gear (19). Make sure the slightly raised
inner teeth on the clutch disc are facing towards
the output end. 14
15
04 Place inner ring (17) onto the clutch disc. Make 16
sure the lugs are facing towards the output end.
17
05 Fit intermediate ring (16) so that the lugs engage 18
in the clutch disc recesses.
13
06 Fit outer ring (15). Make sure the lugs are facing
towards the output end.
07 Use three coupling elements (13) to align the lugs
on the outer ring with the lugs on the inner ring.
Position the lugs on the inner and outer rings 013156
directly in line with the coupling elements so that

the coupling elements will later fit into the
recesses in synchronizer hub (14) and over the
lugs. Remove the coupling elements once the
parts have been correctly aligned.
08 Heat synchronizer hub (14) to approx. 120 °C and
slide it onto the main shaft spline. At this point,
the positioned lugs must be located in the recesses
on the synchronizer hub. The catches on the outer
ring must engage in the recesses on the
synchronizer hub. Drive the synchronizer hub
fully home using a plastic drift if necessary.
09 There must be 0.2 ÷ 0.45 mm axial play on
helical gear (19).
10 Insert coupling elements (13) into synchronizer
hub (14).
7-3
Main shaft 6 S 850 / 6 S 890
11 Push sliding sleeve (12) over the synchronizer

hub and outer ring so that it rests against the
clutch disc.
12 Insert new compression springs and the used
pressure pieces into the synchronizer hub, making
sure they are the right way round (see fig.
013156).
13 Use a suitable tool to guide the pressure pieces
8
into the synchronizer hub and sliding sleeve.
9
14 Check that the synchronizer parts have not 10
11
15 Fit outer ring (11). The lugs must engage in the 12
coupling elements and the catches must engage in
the recesses on the synchronizer hub.
16 Insert intermediate ring (10). The lugs must be
facing towards the output end. Insert inner ring
(9) and make sure the lugs engage in the coupling
elements. 2
3
17 Fit clutch disc (8) so that the raised inner teeth are 1
facing towards the input end and bring it into
mesh with intermediate ring (10). Move the
5
sliding sleeve to neutral position, pressing against 4
the clutch disc at the same time. You will be able
to hear the pressure pieces clip into place.
6
18 Attach circlip (7). 7
NOTE
The axial play on the circlip should be 0 ÷ 0.1 mm.
Select a suitable circlip to ensure this is the case.
19 Lightly oil needle cage (6) and insert it together 013157
with 1st speed helical gear (4). The engaging
teeth should mesh with clutch disc (8).
20 Heat clutch body (5) to approx. 120 °C and fit it.
21 The axial play on helical gear (4) should be
0.15 ÷ 0.50 mm.
22 Heat reverse gear wheel (1) with needle cage (3)
and thrust bush (2) to approx. 120 °C and fit
them.
7-4
6 S 850 / 6 S 890 Main shaft
23 Lightly oil needle cage (42) and fit it together

40
with 3rd speed helical gear (41). Make sure the
engaging teeth are facing towards the input end. 39
24 Check that the synchronizer parts have not 37

38
25 Fit synchronizer ring (39) and clutch body (40) 36
onto the helical gear's engaging teeth. 35
26 Heat synchronizer hub (38) to 120 °C and slide it 34
onto the main shaft spline until it is flush.
Use a plastic drift to drive it fully home if
necessary. The catches on the synchronizer ring
must engage in the recesses on the synchronizer
hub.
27 The axial play on helical gear (41) should be 42
0.20 ÷ 0.45 mm. 41
28 Fit sliding sleeve (37). Make sure the flat side is
facing towards the input end.
NOTE
The recesses on the inside of the sliding sleeve
must be in line with the points on the
013158
synchronizer hub designated for the compression
springs and pressure pieces.
29 Press new compression springs and the used
pressure pieces into the bores on the synchronizer
hub and guide them into the sliding sleeve.
31 Fit synchronizer ring (36) so that the catches
engage in the recesses on the synchronizer hub.
32 Place clutch body (35) onto the synchronizer ring.
33 Pull the sliding sleeve into neutral position,
pressing on synchronizer ring (36) and clutch
body (35) while doing so. You will hear the
pressure pieces clip into place.
NOTE
The axial play on the circlip should be 0 ÷ 0.1 mm.
Select a suitable circlip to ensure this is the case.
7-5
Main shaft 6 S 850 / 6 S 890
35 Lightly oil needle cage (33) and fit it together

with 4th speed helical gear (32). The engaging 27
teeth should mesh with clutch body (35). 26
24
36 Fit disc (31) and attach circlip (30).
37 Lightly oil needle cage (29) and fit it together 23 25
with 6th speed helical gear (28). Make sure the
engaging teeth are facing towards the input end. 22

39 Fit clutch body (27) and synchronizer ring (26)
onto the helical gear's engaging teeth. 32
40 Heat synchronizer hub (25) to 120 °C and slide it 33

onto the main shaft spline until it is flush. 31
Use a plastic drift to drive it fully home if 30
necessary. The catches on the synchronizer ring 29
must engage in the recesses on the synchronizer 28
hub.
41 The axial play on helical gear (32) should be
0.25 ÷ 0.65 mm.
42 Fit sliding sleeve (24).
NOTE
The recesses on the inside of the sliding sleeve
must be in line with the points on the
synchronizer hub designated for the compression
springs and pressure pieces.
43 Press new compression springs and the used 013159
pressure pieces into the bores on the synchronizer
hub and guide them into the sliding sleeve.
45 Fit synchronizer ring (23) so that the catches
engage in the recesses on the synchronizer hub.
46 Place clutch body (22) onto the synchronizer ring.
47 Pull the sliding sleeve into neutral position,
pressing on synchronizer ring (23) and clutch
body (22) while doing so. You will hear the
pressure pieces clip into place.
7-6
6 S 850 / 6 S 890 Main shaft

21
NOTE
The axial play on the circlip should be 44
0 ÷ 0.05 mm. Select a suitable circlip to ensure 43
this is the case.
49 Slide inner ring (44) onto the main shaft and
attach circlip (43).
013160
7-7
6 S 850 / 6 S 890 Layshaft
4
a b
3
2
1
017306
8 Layshaft
Dismantling Assembly
NOTE
Fig. shows the over-drive version. In the through- ! DANGER
drive version the helical gears Items 3 and 4 are Ensure protective gloves are worn when handling
reversed. heated helical gears.
01 Release circlip (1).
01 Ensure bores of helical gears and seats of layshaft
02 Extract taper roller bearing inner races (2 and 8) are free of grease and dust. Heat helical gears to
with grips 1X56 136 724 (input end, Item 2) and 160 ÷ 180 °C and fit on layshaft. Immediately
1X56 136 725 (output end, Item 8). after assembling helical gears, press on further
until they rest with no play.
03 Press off helical gears individually from the
layshaft (7) in view of the high force required ! DANGER
(up to 300 kN).
heated taper roller bearing inner races.
a = through-drive
02 Heat taper roller bearing inner races to approx.
b = over-drive
85 °C and push on until they rest with no play.
03 Fit circlip (1) in front of input end taper roller bea-
ring inner race with 0 ÷ 0.05 mm axial play.
Index a: 00-10-01 8-1

6 S 850 / 6 S 890 Synchronizers
9 Synchronizer
x
9.1 Determining wear limit
5th/6th speed and 3rd/4th speed

Check condition of synchronizer rings and clutch
bodies before assembling synchronizers. 1 2
NOTE
Do not mix up synchronizer parts.
01 Place synchronizer ring (1) onto corresponding
clutch body (2). Turn synchronizer parts so cones
nest evenly and parallel together.
The synchronizer ring wear limit is 0.8 mm in the
case of the 5th/6th and 3rd/4th speed
synchronizers.
02 Using feeler gauge, measure distance (X) between
clutch body and synchronizer ring at two opposing
points. If wear limit is below 0.8 mm, exchange
synchronizer ring and/or clutch body.
03 Check condition of synchronizer parts (visual
check). Replace synchronizer parts if surface is 001999
not flat. Do not mix up parts which have been

inspected together (mark parts accordingly).
1st /2nd speed

01 Place inner ring (3), intermediate ring (2) and
outer ring (1) of 1st/2nd gear synchronizer
onto clutch disc (4). Turn outer ring so cones nest
evenly together. Evenly apply 50 Nm on outer
ring. F 50 N
02 Using a feeler gauge, measure distance (s) bet-
ween clutch disc and outer ring at two opposing
points. The wear limit is 1.5 mm. If distance (s) is
below wear limit, use new intermediate and/or s
outer ring and inner ring.
1 2 3 4
017304
9-1
Synchronizers 6 S 850 / 6 S 890
9.2 Assembling synchronizer

2
9.2.1 Version ZF-BK (5th/6th and 3rd/4th speed)
1
01 Check wear limits according to Section 9.1.
02 Renew compression springs (5). This guarantees
prescribed shift force for sliding sleeve (6).
03 Synchronizers may be subassembled first or
assembled on the mainshaft itself. 4
04 Push sliding sleeve (6) onto synchronizer hub. Ins-
ert new compression springs (5) and pressure pie- 3 5
ces (4) into synchronizer hub (3). Hold drift
against centre of pressure pieces and guide pressu-
re pieces into sliding sleeve (6).
05 Position clutch body (1) and synchronizer ring (2)
and push sliding sleeve (6) into middle position.
NOTE 1a
Ensure correct position of pressure pieces. 2a
6
009510
Sectional view of synchronizer / ZF-BK 6

1 Clutch body
2 Synchronizer ring 2 2a
3 Synchronizer hub 1
5
4 Pressure piece
5 Compression spring 4 1a
6 Sliding sleeve
3
001940
001940
9-2
6 S 850 / 6 S 890 Synchronizers
9.2.2 Version ZF-D (1st/2nd speed)

2
01 Check wear limits according to Section 9.1. 7
8
02 Assembly procedure basically similar to version 1
ZF-BK.
03 Teeth of sliding sleeve (6) have 3 recesses cover-
ing 3 teeth each. Align middle tooth with narrow
recess in synchronizer hub (3) (pressure piece
groove). Renew compression springs.
04 Insert new compression springs (5) and pressure
pieces (4) into synchronizer hub. Fit pressure 4
pieces so round head of pressure piece juts into
5 3
recess in sliding sleeve teeth.
05 Insert couplings (9). 9
06 Insert outer ring (2), intermediate ring (7) and
inner ring (8). 1a
8a
07 Place clutch disc (1) in position. 7a
2a
NOTE
Ensure correct position of pressure pieces. 6
001941
Sectional view of synchronizer / ZF-D

6
1 Clutch disc
1a
2 Outer ring 2 2a
3 Synchronizer hub 7 7a
1
4 Pressure piece 8a
8
5
5 Compression spring 4
6 Sliding sleeve
7 Intermediate ring
8 Inner ring 3
001942
001942
9-3
6 S 850 / 6 S 890 Adjusting shafts
10 Adjusting shafts
10.1 Main shaft - input shaft A

Clutch housing, separate version
NOTE
This measuring and setting are not required for
the integrated clutch housing version.
Measuring and adjusting spacer ring between
input shaft and clutch body
01 Install input shaft in connection housing in acc.
with Section 6.
02 Support connection housing in such a way that
the input shaft hangs free and therefore the
bearing slack towards the outside is removed.
013141
03 Measure distance “A” from joint face of connec-
tion housing to face of ring gear of input shaft.
04 Install main shaft and layshaft in transmission
housing in acc. with Section 4.3.
1
05 Insert existing spacer ring (1) into clutch body.
06 Support transmission housing in such a way B
that the main shaft hangs free and therefore the
bearing slack towards the outside is removed.
07 Fit gasket to transmission housing. Measure
distance “B” from spacer ring to gasket.
Example: 003 192
Distance "A" = 2.0 mm 003192

minus distance "B" = 1.1 mm
(3.2 mm spacer ring)
Difference is
existing clearance = 0.9 mm
Specified clearance = 0.8 to 1.2 mm
08 The fitted spacer ring can be used in this
example.
Index a: 00-10-01 10-1

Adjusting shafts 6 S 850 / 6 S 890
10.2 Layshaft
NOTE
The figure shows measurement of the separate
clutch housing version. Measurement of the inte-
grated clutch housing is the same.
01 Position the gear vertically with the input end
upward for measuring. C
02 Drive back bearing outer race of layshaft evenly
using a soft drift until bearing is free of play
(perceptible). When doing this, constantly rotate
layshaft over input shaft so that rollers of taper
roller bearings line up.
03 Measure distance “C” from connection housing to
bearing outer race. The size of the correct shims
(2 pieces) is calculated as follows:
Example:
Distance “C” 2.95 mm
010100
plus Gasket thickness + 0.40 mm
minus mean clearance
0 - 0.1 mm, – 0.05 mm
Difference is size of
correct shims = 3.30 ±0.05 mm
10-2 Index a: 00-10-01

6 S 850 / 6 S 890 Adjusting shafts
10.3 Connection plate

NOTE
The figure shows measurement of the separate D
clutch housing version. Measurement of the inte-
grated clutch housing is the same.
NOTE
Play/clearance is given. Check only.
01 Measure distance "D" between the connection
plate and the contact ridge for the ball bearing.
02 Measure distance "E" between the ball bearing
and the connection housing face.
Example:
Distance "D" = 8.05 mm
Distance "E" minus
gasket (8.40 mm - 0.40 mm) - = 8.00 mm 013144
existing clearance = 0.05 mm
013145
Index a: 00-10-01 10-3

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2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

5 Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 Main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

10 Adjusting shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

This manual is intended for skilled personnel who have

This manual deals with the standard ZF product in

However, due to continuing development of the product,

Service points equipped by ZF Friedrichshafen AG all

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out

Repair work carried out at ZF service points is

Damage resulting from work performed by non-ZF

SAFETY NOTICE GENERAL INFORMATION

To avoid injury to personnel and damage to pro-

After completion of repair work and testing, skilled staff

! THREATS TO THE ENVIRONMENT !

Remove the old remains of gaskets on all gaskets. REWORKING

BEARINGS d) Duo shaft seals have two packing

f) If possible heat shaft seal bores to between 40 and

a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

* refer to expendable material

Tightening torques for nuts and bolts, extract from

Regular thread Fine screw thread

Size Tightening torque Size Tightening torque

M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1,5 135 200 235

M 18 280 390 460 M 18 x 2 290 420 490

M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991 / checked 1997

Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)

Dimensions Tightening torque Pipe Thread Tightening-

Description Name Approx. Application Remarks

Grease for example:

Description Dimension Measurement device Remarks

01. Axial clearance of bearing 0 mm Depth gauge Clearance given, check

03. Axial clearance of circlips Feeler gauge Adjustment with circlips of

Description Dimension Measurement device Remarks

15. Max. permissible approx. 1 mm Feeler gauge If value is exceeded deter-

17. Backlash of speedometer 0.1 ÷ 0.2 mm Value given, check by hand

18. Wear limit of synchonizer Feeler gauge If measurement is below

19. For information: 0.6 mm Feeler gauge Upper limit of synchronizer

20. For information: 270 ÷ 310 N All compression springs in

21. Distance from housing 7 mm (Depth gauge) (Measure installation size

Description Dimension Measurement device Remarks

29. Tightening torque of 23 Nm Torque wrench Attach washer

30. Tightening torque of 78 Nm Torque wrench

31. Tightening torque of vent 10 Nm Torque wrench

32. Tightening torque for 10 Nm Torque wrench Do not exceed specified

Description Dimension Measurement device Remarks

34. Tightening torque for 50 Nm Torque wrench Fit sealing ring

36. Tightening torque for 45 Nm Torque wrench Fit spacer ring

40. Tightening torque of 45 Nm Torque wrench

0732 040 410 Synchronizers/ZF-D 16.5 1.10 5.90 26.1