Description

ZF 16 K 160 2008 Parts Catalog – What a 44-Page OEM Document Does for You

I’ve had to order a transmission part three times because the aftermarket catalog had the wrong number. That’s time on a lift a customer is paying for, and it’s cash out of my pocket. The ZF 16 K 160 2008 Parts Catalog stops that nonsense. This is a 44-page factory document from ZF Friedrichshafen AG, dated 11.07.2008, with the parts list number 1297 002 187. It’s built for the DaimlerChrysler AG application – a dumper truck, 6×6, 22-ton GVW, with a ZF 16 K 160 transmission. If you’re wrenching on one of these or any commercial vehicle with this gearbox, you need this file open on your tablet, not a third-party chart.

Why an OEM Parts Catalog Beats Aftermarket Sheets

Aftermarket catalogs often merge parts from different years or leave out revision codes. This one is straight from ZF’s internal system – the same lists their dealers use. Each item number (like the ones starting with 1297) links to a specific ZF parts list. The OCR excerpt shows the page 2 detail: “item text A10 CUSTOMER:DAIMLERCHRYSLER AG COUNTRY:D A14 CUST.SPEC.NO: CODE: A16 A6242606000”. That’s the trail that leads to the exact seal, bearing, or shift fork you need. Without it, you’re buying parts that “should fit” – and I’ve seen those leave a transmission on the floor.

Application and Configuration: Dumper 6×6

The catalog lists the vehicle data on page 3: “S04 MODEL:DUMPER * 6X 6 S06 MAX. G.V.M. 22T*MAX. G.C.M. 70T”. That tells you this transmission is in an off‑highway truck with a 70-ton GCWR. The ratio spread is recorded: “F10 RATIO: 13,68- 1,00 *DG G13,68* 9,40* 6,73* 4,79* 3,36* 2,31* G 1,65* 1,17*”. If you’re swapping a gear or rebuilding the countershaft, having those numbers from the factory keeps you from ordering the wrong speed set. The document also notes the input shaft “L=320,0*SAE 10C 2 INCH JOURNAL” and output flange “OD=180 *BOLT=10XM16X1,50X45 L=204,0”. These are dimensions you can’t get from a parts counter phone call.

Oil Capacity and Grade: TE-ML02

Page 3 specifies “M90 OIL CAPACITY: AP. 13,00L” and “M92 OIL GRADE ACC.TO ZF:TE-ML02”. That’s 13 liters of a specific ZF fluid spec. I’ve seen guys pour in ATF because the generic chart said “SAE 50”. That kills synchros. This catalog gives you the exact factory specification – no interpretation needed. The weight of the unit is also noted: “M94 MASS : APPRX. 340,0 KG”. If you’re pulling this transmission, you know you need a 750‑pound-capacity jack and a second set of hands. That’s the kind of real-world data this 44-page document delivers.

7 Key Specifications on a Single Spreadsheet

The technical information sheet on pages 2–3 is a dense table of parameters. Here are the ones I use most on the bench:

• Application: Dumper, 6×6, 22T GVW (page 3)
• Ratio range: 13.68 to 1.00, plus reverse 11.06 and crawler ratios (page 2)
• Control: Remote control, vertical, H‑H pattern (page 2)
• Clutch: Dog clutch version, separate clutch (page 2)
• Input shaft length: 320.0 mm, SAE 10C 2‑inch journal (page 2)
• Oil: 13.0 L of TE‑ML02 grade (page 3)
• Weight: 340.0 kg (page 3)

That last number, combined with the “M82 ASSEMBLY:SHUT-OFF VALVE* F” note, tells you where to put the drain plug and how much fluid to expect. You don’t guess on stuff like that. ZF 16S151 ECOSPLIT III & 16S151 R 2007 Parts Catalog covers a related family, but this 16 K 160 file is the only one with the offset dog‑clutch configuration.

ESX Control and Electronic Override: What the Manual Skips

The catalog mentions “H50 ELECTRONIC: H64 TRANSMITTER INPUT:PREP.*D= *WS”. That’s a note that the housing is prepped for a speed sensor, but it doesn’t include wiring diagrams. For electronic control module diagnostics, you’d want the service manual, not a parts catalog. This document is for identifying the physical parts – shift levers, bearings, oil seals. If you need to trace a circuit, pair this with the ZF service documentation. ZF 16S221 ECOSPLIT III 1316 2007 Parts Catalog OEM Specs will give you a similar format for a different series.

Who Needs This 44-Page Parts Catalog?

If you’re a home garage guy pulling a ZF 16 K 160 from a military surplus truck or a municipal dump truck, you need this. The OEM part numbers on each line (like “1297 002 187”) are the same numbers you give the dealer. Without them, you’re measuring with a caliper and hoping. For professional shops, this catalog saves the “I’ll call ZF and wait” routine. The ZF 16 S 2521 TO 2010 Parts Catalog – OEM Factory Specs is another option for heavier units, but this 44-pager is laser‑focused on the 16 K 160’s specific parts.

Does the catalog include assembly instructions?

No. It’s a parts list, not a service manual. For assembly, you need the ZF workshop manual.

How do I find the right part number for a 16 K 160 transmission?

Cross-reference the “CUST.SPEC.NO.” (A6242606000) and the vehicle model line. The catalog lists every part by figure number (e.g., figure 4) and part number. If you have the transmission serial or application code, match it to the “F10 RATIO” block. Then look for the item text that matches your configuration – the DG*LR*ANGEFL*DW‑SE code tells you it’s a right‑angle, flange‑mounted unit with vertical shift. If the part isn’t in your configuration’s line, it won’t fit. I’ve had to teach four apprentices this trick because they kept ordering parts from the wrong application.

Getting the right part on the first call saves a week. That’s what a factory catalog does. Automotive Industry Overview can tell you about ZF’s role in the market, but this file is what you need on the bench. For electrical specs like battery connections, Automotive Battery might help elsewhere, but for this transmission, stick to the factory parts list. Access the Factory Manual now and keep it in your digital library.