Hey as we're on the topic of Zf's. I got an As-tronic in a Man Tga Tractor unit all the way down in the Caribbean. I'm also having some problems with it. Sometimes when on drive mode. Only on gear number 3. It switches itself to neutral.it wont shift back to any gear be it reverse or forward.
I would start by removing the clutch actuator 4 nuts. Then grab the clutch fork with your hand make sure it movies back and forth easy if not, you can remove it and grease it there is a procedure in the manual for greasing clutch fork. My experence has been the clutch actuator will last for around 500,000 miles +or.
If i try shifting it manually using the select lever. It feels as if the gear is trying to engage but not staying engaged. If i switch off ignition and leave off for approximately one minute and restart truck.
It then engages and drives off as normal. Any suggestions on what might be the problem? When you refer to the transmission actuator, are you talking about the clutch actuator on bottom of trans, or the TCU Transmission Control Unit on top of trans? Another thing to consider when you start the truck the clutch actuator does a self check by cycling the clutch in and out- If the actuator is wore out or not working properly and the clutch fork could be seized up.
![Clutch Actuator Repair Manual Man Tga Clutch Actuator Repair Manual Man Tga](http://img.everychina.com/nimg/45/9b/0e3bcdda04521a1ec9c0d18d6e70-600x600-0/627496am_81326056111_81326556128_heavy_duty_man_tgs_truck_gear_lever_actuator.jpg)
This will not let the transmission go into neutral untill the clutch is able to complete the self check, it will sit there and try every so often to cycle the clutch in and out. I would start by removing the clutch actuator 4 nuts.
Then grab the clutch fork with your hand make sure it movies back and forth easy if not, you can remove it and grease it there is a procedure in the manual for greasing clutch fork. My experence has been the clutch actuator will last for around 500,000 miles +or. If your still using the original you may need to replace it. Hi dear friends, I am new here and my English is no so good, so I hope you'll have nerves to read and hopefully give some kind of help. I am trying to fix an problem with ZF-AS-TRONIC transmission electronic module. When engine is started transmission won't switch to neutral for some time till engine and transmission is heated up.
We have found that if we heat top of the actuator module with heat gun, it speed up this process significantly. According to the operators manual, all this may happens if ambient temperature is below -20 deg. But the problem is that it happens in relatively hot day every time engine is cold started.
As I have found there is oil temp. Sensor in transmission actuator and it is connected to the transmission controller electronic board, but is seems like it is ok. I suspect there is other on-board ambient temp.
Sensor that may be faulty. I've tried to locate this sensor on the printed board but without success. Found this picture here on forum. This is same board as mine.
Can someone help about this problem? I see there are many experts so I hope someone may help me to solve this. Is there some on-board temperature sensor that can be source of this like problem? I will be glad to get any kind of help.
Thanks and best regards.
Removal Procedure. Remove the battery tray. Refer to Battery Tray Replacement. Remove as much brake fluid out of brake fluid reservoir as possible. Unclip the clutch actuator cylinder front pipe from the 2 retainers (1). Remove the retaining clip (1).
Disconnect clutch actuator cylinder front pipe (3) from the clutch master cylinder (2). Remove the retaining clip (1). Disconnect the clutch actuator cylinder front pipe (2) from the clutch actuator cylinder pipe elbow. Remove the clutch actuator cylinder front pipe from the vehicle. Installation Procedure.
Install the clutch actuator cylinder front pipe in the vehicle. Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow. Install the retaining clip (1).
Connect clutch actuator cylinder front pipe (3) to the clutch master cylinder (2). Install the retaining clip (1). Clip the clutch actuator cylinder front pipe into the 2 retainers (1). Install the battery tray.
Refer to Battery Tray Replacement. Bleed the hydraulic clutch system.
Refer to Hydraulic Clutch System Bleeding. Fill the reservoir with GM approved brake fluid from a clean, sealed brake fluid container up to the MAX level. Other materials: Engine Coolant Temperature Sensor Replacement - Radiator Callout Component Name Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling. 1 Retaining C. Rear Wheelhouse Liner Replacement Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
1 Rear Wheelhouse Panel Liner. Special Tools BO-38185 Hose Clamp Pliers EN-45059 Angle Meter For equivalent regional tools, refer to Special Tools.
Removal Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Relieve fuel system pressure.