• Maintenance and Diagnostics Manual MM-0150


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    • Abstract: $25.00Maintenance and Diagnostics Manual MM-0150ZF-FreedomLine TransmissionRevised 06-09 Service NotesZF-FreedomLine TransmissionMaintenance and Diagnostics Manual MM-0150USING THIS MAINTENANCE MANUALThis maintenance manual addresses maintenance, diagnostics and use issues that owners and users of

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Maintenance and Diagnostics Manual MM-0150
ZF-FreedomLine Transmission
Revised 06-09
Service Notes
ZF-FreedomLine Transmission
Maintenance and Diagnostics Manual MM-0150
USING THIS MAINTENANCE MANUAL
This maintenance manual addresses maintenance, diagnostics and use issues that owners and users of
ZF-FreedomLine transmissions may encounter. It is not intended as a discussion of every issue that may
arise in those contexts but is illustrative of certain information that might be considered in conjunction
with installation, maintenance, repair and use of the subject transmissions.
Owners and users of ZF-FreedomLine transmissions are responsible for familiarizing themselves with the
content of this maintenance manual and using the information (and following the warnings) contained
herein for any function or condition covered. They are also responsible for communicating the information
contained in this maintenance manual to any persons performing installation, maintenance or repair
services with respect to the subject transmissions. Correct maintenance, diagnostics and use of the
subject transmissions, and observance of the suggestions and directives contained in this maintenance
manual, are integral requirements of continued warranty coverage for the subject transmissions.
This maintenance manual is provided under the following limitations, restrictions and disclaimers, which
are applicable to any person or entity using or relying on the same, as a condition to such usage or
reliance:
THESE MATERIALS PROVIDE SUGGESTIONS, AS WELL AS CERTAIN REQUIREMENTS, WITH RESPECT TO
THE INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF ZF-FREEDOMLINE TRANSMISSIONS.
INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF THE SUBJECT TRANSMISSIONS IS SOLELY THE
RESPONSIBILITY OF THE OWNERS AND USERS OF THE SUBJECT TRANSMISSIONS, AND IMPROPER OR
INCORRECT ACTIONS OR OMISSIONS IN THAT REGARD ARE NOT THE RESPONSIBILITY OF
ZF FRIEDRICHSHAFEN AG.
WARRANTY OBLIGATIONS WITH RESPECT TO THE SUBJECT TRANSMISSIONS ARE CONTAINED IN THE
WARRANTY INFORMATION MATERIAL ACCOMPANYING THAT PRODUCT. THE INFORMATION IN THESE
MATERIALS IS PROVIDED ON AN ‘AS IS’ BASIS, AND ALL WARRANTIES OF ANY KIND, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR
A PARTICULAR PURPOSE AND NONINFRINGEMENT OF PROPRIETARY RIGHTS ARE EXPRESSLY
DISCLAIMED. CHANGES MAY BE MADE PERIODICALLY TO THE INFORMATION CONTAINED HEREIN.
THOSE CHANGES MAY OR MAY NOT BE INCORPORATED IN ANY NEW VERSION OF THESE MATERIALS,
AND THESE MATERIALS CAN QUICKLY BECOME OUT-OF-DATE.
TO THE EXTENT THAT ANY OPERATION OR FUNCTION DESCRIBED IN THIS MAINTENANCE MANUAL
REQUIRES INTERFACE WITH PRODUCTS, EQUIPMENT OR MATERIALS OF MANUFACTURERS OTHER THAN
ZF FRIEDRICHSHAFEN AG, THE PRODUCTS MANUFACTURED BY ZF FRIEDRICHSHAFEN AG ARE
WARRANTED ONLY AS SEPARATELY SPECIFIED BY ZF FRIEDRICHSHAFEN AG. REFERENCE SHOULD BE
MADE TO THE WARRANTY INFORMATION DOCUMENT ACCOMPANYING THE SUBJECT TRANSMISSION
FOR WARRANTY COVERAGE PROVIDED BY ZF FRIEDRICHSHAFEN AG. ZF FRIEDRICHSHAFEN AG MAKES NO
WARRANTY WITH RESPECT TO PRODUCTS, EQUIPMENT AND MATERIALS MANUFACTURED OR
SUPPLIED BY OTHER ENTITIES OR THE INTERFACE OF THE SUBJECT TRANSMISSIONS WITH OTHER
PRODUCTS, EQUIPMENT OR MATERIALS.
IN NO EVENT SHALL ZF FRIEDRICHSHAFEN AG BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL,
SPECIAL, EXEMPLARY OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; TOWING; CARGO DAMAGE; LOSS OF USE, DATA
OR PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED, AND ON ANY THEORY OF LIABILITY,
WHETHER IN CONTRACT, STRICT LIABILITY OR TORT (INCLUDING NEGLIGENCE OR OTHERWISE)
ARISING IN ANY WAY OUT OF THE USE OF THE INFORMATION CONTAINED HEREIN, EVEN IF
ZF FRIEDRICHSHAFEN AG IS ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
WHILE ZF FRIEDRICHSHAFEN AG HAS MADE EVERY ATTEMPT TO ENSURE THAT THE INFORMATION
CONTAINED IN THESE MATERIALS HAS BEEN OBTAINED FROM RELIABLE SOURCES,
ZF FRIEDRICHSHAFEN AG IS NOT RESPONSIBLE FOR ANY ERRORS OR OMISSIONS OR FOR THE
RESULTS OBTAINED FROM THE USE OF THESE MATERIALS. IN NO EVENT WILL ZF FRIEDRICHSHAFEN
AG BE LIABLE TO ANYONE FOR ANY DECISION MADE OR ACTION TAKEN IN RELIANCE ON THE
INFORMATION IN THESE MATERIALS.
* * * *
Affiliates of ArvinMeritor, Inc., act as the sales and service representatives for various products of ZF Friedrichshafen AG,
under contractual arrangements with ZF Friedrichshafen AG. For answers to product and service questions, and to order
literature, call ArvinMeritor’s Customer Service Center at 866-668-7221 Monday through Friday from 8 a.m. to 8 p.m. EST,
with a 24-hour on-call answer service. You can also visit Literature on Demand at arvinmeritor.com to access and order
product and service literature.
Service Notes
Before You Begin To Order Information
This manual provides maintenance and diagnostic Call OnTrac at 866-668-7221 to order the following
instructions for ZF-FreedomLine transmissions. publications or visit ArvinMeritor’s commercial
Before you begin procedures: vehicle website at www.meritorhvs.com for free
downloads. (Keyword Transmissions).
1. Read and understand all instructions and
procedures before you begin to service ZF-FreedomLine Transmission
components. (Operator Manual TP-20170) (French and
Spanish versions available)
2. Read and observe all Caution and Warning
safety alerts that precede instructions or ZF-FreedomLine Transmission
procedures you will perform. These alerts help (Parts Book PB-0127)
to avoid damage to components, serious ZF-FreedomLine Transmission Maintenance and
personal injury, or both. Diagnostic Manual (MM-0150)
3. Follow your company’s maintenance and ZF-FreedomLine Transmission Fault Code
service, installation, and diagnostics Diagnostics and Wiring Diagram (TP-01110)
guidelines.

4. Use special tools when required to help avoid
serious personal injury and damage to
components.
Y -09
How to Order Tools Specified in This
Manual
AR -18
Call ArvinMeritor’s Commercial Vehicle
Safety Alerts, Torque Symbol and Notes Aftermarket at 888-725-9355 to order Meritor tools.
ET 06
SPX Kent-Moore, 28635 Mound Road, Warren,
RI D
Michigan, 48092. Call the company’s customer
A Warning alerts you to an service center at 800-345-2233, or visit their
WARNING instruction or procedure
P
website at spxkentmoore.com.
that you must follow
O SE
exactly to avoid serious
PR LEA
personal injury and FreedomLine is a product of ZF Friedrichshafen AG.
damage to components. ArvinMeritor is the sole authorized sales and
– A torque symbol alerts you service representative in North America for
class 6-8 trucks for the ZF-FreedomLine
RE
to tighten fasteners to a
Transmissions.
specified torque value.
Information contained in this publication was in
NOTE
T A Note provides
information or suggestions
effect at the time the publication was approved for
NO
printing and is subject to change without notice or
that help you correctly liability. ZF Friedrichshafen AG reserves the right to
service a component. revise the information presented or to discontinue
the production of parts described at any time.
Access Product and Service Information
on Our Website
Visit Literature on Demand at www.meritorhvs.com
to access product, service, aftermarket, and
warranty literature for ArvinMeritor’s truck, trailer
and specialty vehicle components.
-v
Table of Contents
Regulatory Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Model Numbers and Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
12-Speed ZF-FreedomLine
16-Speed ZF-FreedomLine
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
ZF-FreedomLine Fasteners Tightening Torque
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Acronyms Referenced in Manual
Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ZF-FreedomLine Automated Two-Pedal Transmission
Features
ZF-FreedomLine Transmissions Use a Self-Adjusting Integral Clutch
Clutch Features
How the Clutch Operates
Tools Used in This Manual
Approved Oil Lubricant Specifications for ZF-FreedomLine Transmissions . . . . . . . . . . . . . . . . . . . . . .2
Recommended Preventive Maintenance
ZF-FreedomLine Transmissions Fluid Capacities
How to Identify a ZF-FreedomLine Transmission
Shift Module and Joystick
NEUTRAL Button
FUNCTION Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shift-n-CruiseTM Speed Control
Instrument Panel and Shift Module Displays
Instrument Panel Display
System Malfunction Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
What to do if a System Malfunction Occurs
System Self-Check Status
System Air is Low
Clutch Overload Status
Clutch Wear Warning
How to Shift the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Automatic Mode
Manual Mode
Parking a Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shift Labels
Section 2: Fault Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Before You Make a Warranty Repair on a ZF-FreedomLine Transmission
Fault Codes and Volt-Ohm Meter (VOM) Diagnostics
Fault Codes
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using the ZF-FreedomLine Shifter
Active SAE and ISO Fault Codes
Inactive Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
To View Active or Inactive Fault Codes Again
How to Clear Inactive Fault Codes from TCU Memory
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using a Steering Column-Mount Shift Lever
Active Fault Codes
Inactive Fault Codes
Table of Contents
How to Clear Inactive Fault Codes from the Instrument Panel Display Using a Steering
Column-Mount Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to Retrieve Active and Inactive ISO Fault Codes from the Instrument Panel Display
Using an SAE J1939 Push-Button Shift Lever
Active ISO Fault Codes
Inactive ISO Fault Codes
How to Clear Inactive Fault Codes from the Instrument Panel Display Using an SAE J1939
Push-Button Shift Lever
SAE Fault Code Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ISO Fault Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 3: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Release Fork Greasing Procedure (Standard and Roller Fork Applications)
SAE J1939 Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pneumatic Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
No-Start Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PTO Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Section 4: Wiring/Pneumatic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Resistance Specifications
Diagnostic Connector
Connector Pin Assignments
Section 5: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Transmission
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Voltage Doubler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ZF-FreedomLine Transmission Electronic Controller (ZMTEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Transmission Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Output Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Input Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Output Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Air Filter Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TCU Top Half/Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Transmission Control Unit (TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Shift Rail/TCU Cylinder Adjustments for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Adjust the Cylinder Pistons
Selector Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Travel Sensors Engage, Splitter, Range and Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Transmission Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Cooler By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Output Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Clutch Actuator Housing and Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Regulatory Guidance
Regulatory Guidance
Regulatory Guidance
All persons working with, handling or exposed to
the area where work on the transmission occurs,
are warned to consult and comply with all
applicable health, safety, medical or environmental
standards and regulations governing non-asbestos
fibers.
References to OSHA, NIOSH, MSHA, and EPA,
which are regulatory agencies in the United States,
are made to provide further guidance to employers
and workers employed within the United States.
Employers and workers employed outside of the
United States should consult the regulations that
apply to them for further guidance.
i
Model Numbers and Ratios
Model Numbers and Ratios
M O – 16 Z 12 A – A 16
ZF-FreedomLine Highest Torque
in Top Two Gears
O = Overdrive Ratio 13 = 1350 lb-ft
No Letter = Direct Drive A 14 = 1450 lb-ft
15 = 1550 lb-ft
16 = 1650 lb-ft
Torque Rating 12 = 12-Speed
13 = 1350 lb-ft 16 = 16-Speed
14 = 1450 lb-ft
15 = 1550 lb-ft
16 = 1650 lb-ft A = Fully Automated
Platform
Z = ZF-FreedomLine 4002082b
12-Speed ZF-FreedomLine
Torque
Transmission Model Rating Overall Rev. Rev.
Description Number lb-ft Ratio L H Ratio and Percent Step
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12
12-Speed M-13Z12A-A13 1,350 15.86 14.68 14.68 11.41 15.86 29 12.33 29 9.57 29 7.44 27 5.87 28 4.57 32 3.47 28 2.70 29 2.10 29 1.63 26 1.29 29 1.00
Direct Drive
M-14Z12A-A14 1,450
12-Speed MO-13Z12A-A13 1,350
Overdrive MO-14Z12A-A14 1,450 15.81 14.62 11.41 8.88 12.33 29 9.59 29 7.44 29 5.78 26 4.57 29 3.55 31 2.70 29 2.10 29 1.63 28 1.27 27 1.00 28 .78
MO-15Z12A-A15 1,550
MO-16Z12A-A16 1,650
16-Speed ZF-FreedomLine
Torque
Transmission
Model Rating Overall Rev. Rev.
Description Number lb-ft Ratio L H Ratio and Percent Step
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12 % 13 % 14 % 15 % 16
16-Speed MO-13Z16A-A13 1,350
Overdrive
MO-14Z16A-A14 1,450 17.01 15.75 13.07 10.81 14.12 21 11.68 22 9.54 21 7.89 21 6.52 21 5.39 18 4.57 21 3.78 22 3.09 21 2.56 22 2.09 21 1.73 21 1.43 21 1.18 18 1.00 20 0.83
MO-15Z16A-A15 1,550
MO-16Z16A-A16 1,650
ii
Torque Specifications
ZF-FreedomLine Fasteners Tightening Torque
Torque Specification
Description Size (lb-ft) (N•m)
Drain plug M24 x 1.5 44 60
Fill/Spill plug M24 x 1.5 44 60
Fill plug (optional, located on the PTO cover) M24 x 1.5 44 60
Neutral switch M20 x 1.5 33 45
Output shaft speed sensor M20 x 1.5 15 21
Air line fittings M16 x 1.5 15 21
Cooler by-pass tubes M30 x 1.5 36 50
Oil line fittings M22 x 1.5 66 90
Bolt, clutch cover to flywheel (Cummins, Caterpillar and Mercedes 7/16-14 Consult the OEM. Consult the OEM.
engines)
Bolt, clutch cover to flywheel (Detroit Diesel, Volvo and Mack engines) M10 Consult the OEM. Consult the OEM.
Bolt, transmission case to flywheel housing 7/16-14 Consult the OEM. Consult the OEM.
Bolt, fork to front cover M12 85 115
Bolt, quill tube to front cover M8 17 23
Bolt, clutch inspection cover to transmission case M8 17 23
Nut, clutch actuator to transmission case M8 17 23
Stud, clutch actuator to transmission case M8 7 10
Vent plug, clutch actuator M12 x 1.5 16 22
Bolt, TCU to transmission case M8 17 23
Vent, TCU M8 7 10
Bolt, bottom accessory bracket to case M10 36 50
Bolt, bottom accessory bracket to case (rear-most position of configuration M12 58 79
2 only)
Bolt, top accessory bracket to bottom accessory bracket 5/16-18 11 15
Stud, top accessory bracket to bottom accessory bracket 5/16-18 to M8 11 15
Bolt, ZMTEC to top accessory bracket 1/4-20 12 16
Bolt, voltage doubler to top accessory bracket 1/4-20 12 16
Bolt, lifting hook to housing M12 58 79
Bolt, PTO cover to housing (International vehicles only) M12 58 79
Bolt, output shaft seal retainer to transmission case M10 34 46
Bolt, yoke retaining plate to output shaft M12 89 120
Stud, transmission case (Volvo only) M10 to M10 36 50
Bolt, oil cooler hose L bracket to housing (3 of 4) M10 36 50
Bolt, oil cooler hose L bracket to housing (1 of 4) M12 58 79
Bolt, oil cooler clip to L bracket 1/4-20 10 14
Bolt, oil cooler bottom mounting bracket to transmission case M12 34 46
Bolt, oil cooler top mounting bracket to bottom mounting bracket 1/4-20 12 16
Bolt, transmission wiring harness to ZMTEC 1/4-20 7 9.5
iii
Acronyms
Acronyms Referenced in Manual
ABS — Anti-Lock Braking System
ACC — Accessory
ASR — Anti-Slip Regulation
CAN — Controller Area Network
CCVS — Cruise Control/Vehicle Speed
EBC1 — Electronic Brake Controller #1
ECM — Engine Control Module
ECU — Electronic Control Unit
EEC1 — Electronic Engine Controller #1
EEC2 — Electronic Engine Controller #2
EEPROM — Electronically Erasable Programmable Read Only Memory
ERC1 — Electronic Retarder Controller #1
ETC1 — Electronic Transmission Controller #1
ETC2 — Electronic Transmission Controller #2
ISO — International Standards Organization
OEM — Original Equipment Manufacturer
PSI — Pounds Per Square Inch
PTO — Power Take-Off
SAE — Society of Automotive Engineers
TC1 — Transmission Controller #1
TCU — Transmission Control Unit
WSI — Wheel Speed Information
ZMTEC — ZF Meritor Electronic Transmission Controller
iv
Section 1
Introduction
ZF-FreedomLine Automated
Introduction
Section 1 The clutch has a stamped housing and snap-in
connection between the release bearing and
Two-Pedal Transmission diaphragm spring. The housing contains the
This manual provides maintenance and service shipment cups, diaphragm spring, pressure plate,
information for the ZF-FreedomLine automated spring straps, and snap-in bearing connection.
two-pedal transmission. To order information on The single-plate clutch disc assembly has a
other Meritor transmission models, refer to the cushioned, riveted organic facing material for
Service Notes page at the front of this publication. smooth clutch engagement.
Features The clutch disc is designed with two torsional
dampeners: A six-spring main dampener, which
ZF-FreedomLine transmission models are helps to reduce drivetrain wear that results from
available in 12-speed direct and overdrive, and engine torsion; and a six-spring pre-dampener,
16-speed overdrive to meet a variety of application which helps to reduce engine gear noise.
requirements.
ZF-FreedomLine transmissions are automated How the Clutch Operates
with integrated electronics for worry-free shifting. The ZF-FreedomLine transmission control unit
An operator can easily switch to manual control at (TCU) controls the clutch actuator cylinder, which
any time. engages the clutch. The actuator checks clutch
The exclusive “no clutch pedal” design completely travel and adjusts clearances as required.
eliminates clutch pedal actuation for starts and
stops, freeing operators from potential distractions
and extending clutch life. The ZF-FreedomLine shift Figure 1.1
module enables less-experienced operators to shift CLUTCH DISC CLUTCH HOUSING
as well as seasoned veterans.
Torque ratings range from 1,350 lb-ft to 1,650 lb-ft RELEASE
for today’s high torque, low rpm engines. BEARING
A twin countershaft with full helical gearing sets
industry standards for quiet, long-life operation.
An aluminum case yields a weight savings of up
to 132 pounds.
ZF-FreedomLine Transmissions Use
a Self-Adjusting Integral Clutch
Tools Used in This Manual
Clutch Features SPX Kent-Moore specifies the following tools in
The integral clutch is self-adjusting. The release this manual. Refer to the Service Notes page on
bearing is permanently-lubricated and sealed for the inside front cover for instructions to order
maintenance-free operation. these tools.
The clutch is air-operated and electronically- Seal Remover (part number J-24171-A)
controlled. Yoke Puller (part number J-7804-01)
Input Shaft Turning Tool (part number J-45556)
Clutch adjustment and wear are continually Output Shaft Seal Installer (part number J-45247)
monitored, so no clutch adjustment is necessary.
An in-cab display indicates when to replace the
clutch.
1
Section 1
Introduction
Approved Oil Lubricant ZF-FreedomLine Transmissions Fluid
Specifications for ZF-FreedomLine Capacities
Transmissions
Transmission Oil Capacity (Quarts)
12 sp Direct Drive 12.7
WARNING 12 sp Overdrive 12.7
Use of inappropriate oil may damage the 16 sp Overdrive 13.5
transmission.
Do not use multi-viscosity or EP (extreme pressure
additive) oils. How to Identify a ZF-FreedomLine
Transmission
NOTE: The ZF-FreedomLine transmission is
designed to be used only with 50 weight synthetic You can identify a ZF-FreedomLine transmission
oil. from the identification plate located on the left side
of the transmission. Refer to Model Numbers and
NOTE: The following partial listing shows Ratios at the beginning of this manual.
lubricants that have been approved for use with
ZF-FreedomLine transmissions. If your intended Shift Module and Joystick
lubricant is not listed, prease contact OnTrac at
866-668-7221. The ZF-FreedomLine transmission’s shift module,
designed with a joystick, is located next to the
Specification
driver’s seat. The shift module replaces the
standard shift lever, shift tower and shift knob.
Cognis Emgard SAE 50 Synthetic Transmission Lube
Move the joystick FORWARD to upshift and
BP Syn-Gear CD-50 BACKWARD to downshift (manual mode only).
Chevron Delo Synthetic Transmission Fluid SAE 50 Figure 1.2.
Texaco Syn-Star TL SAE 50
Conoco Phillips Family Synthetic Transoil 50
Figure 1.2
Mobil Delvac Synthetic Transmission Fluid 50
Fleetrite Synthetic SAE 50 Transmission Oil Joystick
Kenworth SAE 50 Original Factory Fill Fluid NEUTRAL Button
®
Shell Spirax GSX SAE 50 Shift Module Display
®
Pennzoil Long-Life™ Transmission Fluid EW-50 Shift-n-Cruise TM
Speed Control
Valvoline HD Synthetic Trans Oil SAE 50
Buttons
FUNCTION Button
Recommended Preventive
Maintenance
WARNING
When you install a fill plug and a drain plug into a NEUTRAL Button
transmission, first manually position the plug, and
then install and tighten it by hand. When you’ve Press and release the NEUTRAL button at any time
hand tightened the plug, use a torque wrench to to shift into Neutral.
tighten it to 44 lb-ft (60 N•m). Do not overtighten Press and hold the NEUTRAL and FUNCTION
the plug. Damage to the aluminum housing can buttons at the same time to list active fault codes
result. T on the instrument panel display.
Press and hold the NEUTRAL button, FUNCTION
Item Interval (Miles) button and service brake at the same time to list
Lubricant level inspection 10,000 inactive fault codes on the instrument panel
Visual leak inspection 10,000 display.
Visual release bearing inspection 10,000
Clear the inactive codes 10,000
2
Section 1
Introduction
FUNCTION Button Instrument Panel and Shift Module
Press and release the FUNCTION button to switch Displays
between automatic and manual mode, move into
Both the instrument panel display and the shift
Reverse from a stop, and skip shift (manual mode
module display illuminate to provide operating
only).
information, as well as alert you that a system
Moving into reverse is FUNCTION button malfunction has occurred.
+ DOWNSHIFT (pull back lever) at standstill.
Instrument Panel Display
FUNCTION + UP/DOWNSHIFT results in a skip
shift in manual mode at standstill and when Status Display
driving.
The system is performing a self-check. CH
Press and hold the FUNCTION button and
NEUTRAL button at the same time to list active The transmission is in Neutral. N
fault codes on the instrument panel display. ▲ ▲
No ▼= Automated mode ▼ 12
(example shows 12th gear engaged)
Press and hold the FUNCTION button, NEUTRAL

button and service brake at the same time to list No ▼ = Manual mode 12
inactive fault codes on the instrument panel (example shows 12th gear engaged)
display. Reverse Low is engaged. RL
Shift-n-CruiseTM Speed Control Reverse High is engaged. RH
System Malfunction SM
WARNING System air is low. AL
Only use the Shift-n-Cruise speed control feature
TM
A clutch overload occurred. CL
when you operate a vehicle under normal
operating conditions. Do not use this feature in Clutch wear indicator (the clutch requires CW
replacement)
heavy traffic or on winding, wet or slippery roads.
These conditions can affect cruise control NO DATA (the SAE J1587 info is absent or ––
performance, which can result in loss of vehicle possible loss


Use: 0.0191