"D", "E1", "E2" Brake & 2ND Gear Free-Wheel: Disassembly

1. Remove needle bearings and cylinder "D-E". Remove brake clutch "D" snap ring and clutch pack. See Fig 1 . Using appropriate spring compressor, press spring plate and remove split retaining ring. Remove spring plate. Apply compressed air to oil feed hole to force brake clutch "D" piston from cylinder. Remove piston and "O" ring from cylinder.
2. Remove snap ring and bushing from cylinder "D-E". Remove 2 "O" rings from bushing. Remove snap ring from "E2" brake clutch and remove clutch pack. Using appropriate spring compressor, press spring plate and remove snap ring. Remove spring plate. Apply compressed air to oil feed hole to force brake clutch "E2" piston from cylinder "D-E". Remove piston and remove and discard 2 "O" rings from piston.
3. Remove snap ring from brake clutch "E1" and remove clutch pack. Using appropriate spring compressor, press spring plate and remove split retaining ring. Remove spring plate. Apply compressed air to oil feed hole to force brake clutch "E1" piston from cylinder "D-E". Remove piston. Ensure that seal lip is not damaged during removal or storage of piston.
4. Disassemble planetary drive assembly. Remove 2nd gear free-wheel, thrust washer and needle bearing from brake clutch "E2" carrier. Remove snap ring and disassemble free-wheel while noting assembly order. Using 2 screwdrivers, pry off brake clutch "E2" carrier.

Fig 1: "D", "E1", "E2" Brake & Free-Wheel Components

Courtesy of ZF GETRIEBE GMBH SAARBRUCKEN