REPAIR MANUAL

W 390 MS torque converter

4149 751 606a

Subject to technical changes

Copyright by ZF

This documentation is 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

ZF Friedrichshafen AG, MC-C / 2002-06

Edition: 2002-06

4149 751 606a

W 390 MS
torque converter Table of contents

Page

Preface ................................................................................................................................................................ 4

Important information ........................................................................................................................................... 5

Instructions for repairs .......................................................................................................................................... 6

Tightening torques................................................................................................................................................. 8

Consumables ......................................................................................................................................................... 10

Adjustment data..................................................................................................................................................... 11

Cross-section ......................................................................................................................................................... 12

Special tools ......................................................................................................................................................... 13

1 Removing and installing torque converter .................................................................................................. 1-1

1.1 Removing torque converter ......................................................................................................................... 1-1

1.2 Installing torque converter .......................................................................................................................... 1-5

1.2.1 Measuring torque converter end float ......................................................................................................... 1-5

1.2.2 Measuring torque converter installation dimension .................................................................................... 1-9

2 Dismantling and assembling torque converter ............................................................................................ 2-1

2.1 Dismantling torque converter ..................................................................................................................... 2-1

2.1.1 Dismantling stator....................................................................................................................................... 2-3

2.1.2 Assembling stator........................................................................................................................................ 2-5

2.1.3 Dismantling circuit cover ............................................................................................................................ 2-7

2.1.4 Assembling circuit cover............................................................................................................................. 2-9

2.1.5 Measuring end float of axial bearing (take measurement for checking purposes) ...................................... 2-13

2.2 Assembling torque converter ...................................................................................................................... 2-15

3 Checking torque converter for seal integrity .............................................................................................. 3-1

4149 751 606a 3

W 390 MS
torque converter Preface

This repair manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out mainte-
nance 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 not contained in this manual.

We recommend that work done on your ZF product is

carried out only by skilled mechanics who have had
their practical and theoretical knowledge updated on a
regular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG all

over the world offer you:

1. Continually 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 utmost care.

Warranty:
Repair work carried out at ZF service points is
subject to the contractual conditions prevailing in
the individual case.
ZF FRIEDRICHSHAFEN AG
Commercial Vehicle /Special Transmissions Division Damage resulting from work performed by non-ZF
Service Plant 2 personnel in an improper and unprofessional manner
Tel.: 00 49 / 75 41 77-0 and any consequential costs are excluded from the con-
Fax: 00 49 / 75 41 77-5726 tractual liability agreement. Exclusion of liability also
Internet: www.zf.com applies if genuine ZF spares are not used.

4149 751 606a 4

W 390 MS
torque converter
SAFETY NOTICE
Companies repairing ZF units are responsible for their
own work safety.
To avoid injury to personnel and damage to pro-
ducts, all safety regulations and legal requirements
which apply to repair and maintenance work must
be adhered to.
Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on ZF products
must receive appropriate training in advance. It is the
responsibility of each company to ensure that their
repair staff is properly trained.
The following safety instructions appear in this
manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
! DANGER
This is used when lack of care could lead to
personal injury or death.
4149 751 606a
Important information
GENERAL INFORMATION
Read this manual carefully before starting any tests or
repair work.
CAUTION
Pictures, drawings and components do not always
represent the original object, but are used to illustrate
working procedures.
Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be
drawn (even within a complete illustration).
Always follow the working steps as described in the
text.
After completion of repair work and testing, skilled staff
must satisfy themselves that the product is functioning
correctly.
! THREATS TO THE ENVIRONMENT !
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water or sewage system.
Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants
and cleaning agents in accordance with
environmental protection guidelines.
When working with lubricants and cleaning
agents always refer to the manufacturers
instructions.
CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.
5
W 390 MS
torque converter
In case of doubt always turn to the relevant depart-
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed expertly
and under clean conditions.
Use specified tools to dismantle and assemble trans-
missions.
After removing the transmission from the vehicle,
clean thoroughly with a suitable cleaning agent before
opening.
Pay particular attention to the projections and recesses
of housings and covers when cleaning.
Parts joined with Loctite are easier to separate if
warmed with a fan heater.
CLEANING PARTS
Remove remains of old gaskets on all seal-faces. Care-
fully remove burrs or similar patches of roughness using
an oil-stone.
Lube bores and grooves must be free of anti-corrosion
agents and foreign matter; check for perfect passage.
Carefully cover opened transmissions to prevent foreign
matter from entering.
REUSING PARTS
Parts such as ball or roller bearings, multi-discs, thrust
washers etc., must be inspected by a competent person,
who should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered from
excessive wear.
4149 751 606a
Instructions for repairs
GASKETS, LOCKING PLATES
Parts which cannot be removed without being damaged
must always be replaced with new parts (e.g. gaskets
and locking plates).
SHAFT SEALS
Always change shaft seals with rough, ripped or
hardened packing washers. Seal contact surfaces must
be totally clean and in perfect condition.
REWORKING
Rework may be carried out on seal contact surfaces
using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
riffling.
If rework is needed on distance washers, shims etc.
because of clearance settings, ensure that the reworked
areas contain no face runout and have the same surface
quality.
TRANSMISSION ASSEMBLY
Find a clean site to assemble the transmission. Gaskets
are installed without the use of sealing compound or
grease. When measuring silicon-coated gaskets, take
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.
6
W 390 MS
torque converter
BEARINGS
If bearings are mounted in heated condition, they are to
be heated evenly (e.g. heating cabinet).
Temperature should be at approx. 85 C and must not
exceed 120 C. Each mounted bearing must be oiled
with operating oil.
SEALING
If a specific sealing agent* is to be used for sealing,
comply with the manufacturers directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing to enter oil ducts
and bores. On oil-carrying ducts and bores, wipe off the
sealing agent on the surfaces to be sealed near apertures
to ensure that no sealing agent enters the oil feeds when
the surfaces are sealed.
SHAFT SEALS
a) Apply a light coat of sealing agent* on outer edge of
shaft seals with steel surround.
b) Never apply sealing agent to shaft seals with
rubber surround, but apply a thin coat of Vaseline
8420 to the outer edge or wet with a lubricant, e.g. a
water-soluble, concentrated washing-up liquid (e.g.
Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber surrounds should be
treated on the outer edge of the rubber surround as
described above in section b).
4149 751 606a
Instructions for repairs
d) Dual shaft seals have two sealing
lips. The dust-proof sealing lip (X)
must face outwards.
X
e) Fill the gap between the sealing
lips so it is 60 % filled with grease (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 (makes fitting easier). Press the seal shaft with
mounting or faceplate onto the relevant installation
depth plan.
RETAINING AGENTS
Retaining agents* may only be used in places as
specified in the parts list.
Always comply with manufacturers directions for use
when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
TRANSMISSION OIL
After completing repairs, fill transmissions with trans-
mission oil. For the procedure and approved oils, refer
to the transmission operating manual and List of Lubri-
cants TE-ML (refer to identification plate) which are
available from any ZF After-Sales Service Point and on
the internet under www.zf.com.
After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
specified torques.
* refer to expendable material
7
W 390 MS
torque converter Tightening torques

Tightening torques for nuts and bolts, extract from

ZFN 148

This standard applies to bolts acc. to DIN 912, DIN 931,
DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO
4014, ISO 4017, ISO 8765, ISO 8676, and to nuts acc. to
DIN 934 as well as ISO 4032, ISO 8673.
This Standard contains data on tightening torques (MA)
for bolts and nuts in strength categories 8.8, 10.9 and
12.9, and nuts in strength categories 8, 10 and 12.
Surface condition of bolts: thermally blackened and
oiled or galvanized and oiled or galvanized, chrome-
plated and oiled.
Tighten screws with a calibrated torque spanner or
wrench.
NOTE
Irregular tightening torques are listed separately in the
Repair Manual.

Regular screw thread Fine screw thread

Size Tightening torque Size Tightening torque

(Nm) for (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12

M4 2.8 4.1 4.8 M8x1 24 36 43

M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14 16.5 M10x1 52 76 89

M7 15 23 28 M10x1.25 49 72 84
M8 23 34 40 M12x1.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145

M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500

Edition: August 1991/ checked 1997

4149 751 606a 8

W 390 MS
torque converter Tightening torques

Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643

The screw plug tightening torques MA were determined
according to DIN 7604 for screwing into steel, grey cast
and aluminum alloys.
The values are based on experience and are
intended as reference values for the fitter.
The values for the tightening torque MA apply analo-
gously for screw plugs according to DIN 908 and
DIN 910, as the thread geometries are almost identical.
General rule: Screw/bolt class 5, ZFN 148-1
Screw/bolt material: steel acc. to
DIN 7604. Surface condition: as manu-
factured (without surface protection) and
lightly oiled or galvanized, chromated and
lightly oiled.
The tightening torques MA were determined for
screwing into steel, grey cast and aluminum alloys.
The values are based on experience and are intended
as reference values for the fitter.
General rule: screw/bolt class 5, ZFN 148-1
Material: 9SMnPb28K acc. to DIN 1651
Surface condition: as manufactured
(without surface protection) and lightly
oiled or galvanized, chromated and
lightly oiled.

Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)

Dimensions Tightening torque Pipe Thread Tightening

in Nm screwed into outer torque
steel/gray cast Al alloy diameter in Nm
M8x1 20* 10* 4-5 M8x1 20 - 25
M10x 1 25 / 30* 15 / 20*
M12x1.5 35 25 6 M10x1 25 - 35
M14x1.5 35 25
M16x1.5 40 30 8 M12x1.5 30 - 40
M18x1.5 50 35
M20x1.5 55 45 10 M14x1.5 35 - 40
M22x1.5 60 / 80* 50 / 65*
M24x1.5 70 60 12 M16x1.5 45
M26x1.5 80 / 105* 70 / 90*
M27x2 80 70 15 M18x1.5 50
M30x1.5 100 / 130* 90 / 130*
M30x2 95 85 18 M22x1.5 60
M33x2 120 110
M36x1.5 130 115 22 M26x1.5 90
M38x1.5 140 120
M42x1.5 150 130 28 M30x1.5 130
M42x2 145 125
M45x1.5 160 140 35 M38x1.5 140
M45x2 150 130
M48x1.5 170 145
M48x2 160 135
M52x1.5 180 150
M60x2 195 165
M64x2 205 175
* DIN 7604 Form C
Edition: October 1995

4149 751 606a 9

W 390 MS
torque converter Consumables

Description Name Approx. Application Comments

ZF item number quantity

Grease For example General assembly aid

0750 199 001 Spectron FO 20

Grease Techn. Vaseline 8420 General assembly aid

0671 190 016

NOTE: Inquire as to size of containers before placing any orders.

4149 751 606a 10

W 390 MS torque converter
Description
01. Torque converter
installation dimension
(depending on version)
02. Torque converter end
float between face end
of converter internal
sprang race and spacer
ring on stator hollow shaft
03. Clutch disc clearance
of torque converter
lock-up clutch
04. End float of axial bearing
in torque converter
05. Maximum pressure for
testing seal integrity of
torque converter
06. Tightening torque of
36 hex bolts (M10x22)
on torque converter
07. Tightening torque of
M16 cylindrical screw in
turbine shaft
08. Tightening torque of
M 33x2 screw plug in
torque converter
09. Tightening torque of 24
cylindrical screws
(M10x30) on circuit cover
4149 751 606a
Adjustment data
Dimension Measurement device Comments
81.25 0.5 mm Depth gauge Installation dimension
measured from mounting
face on torque converter to
mounting face on trans-
mission housing.
Installation dimension can
be adjusted using one or
more spacer rings on the
stator hollow shaft.
0.3 to 0.4 mm Depth gauge End float can be adjusted
using shim on face end of
turbine shaft.
OTK 0730 005 591
0.6 to 1.2 mm Feeler gauge Clutch disc clearance is
measured between end disc
and inner clutch disc
0 to 1.1 mm GO gauge and depth Only take check
gauge measurement
2.5 +0.5 bar Forcing device Torque converter test is
1X56 137 129, carried out under water
pneumatic unit using air
1X56 137 130 and
water tank
65 Nm Torque wrench
180 to 190 Nm Torque wrench and Use counter holder
retaining fixture 1X56 137 658 to lock
1X56 137 158 torque converter
190 to 210 Nm Torque wrench Fit new Cu seal. Use counter
holder 1X56 137 658 to lock
torque converter in place
69 Nm Torque wrench
11
W 390 MS
torque converter Cross-section

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

31 30 29 28 27 26 25 24 23 22 21 20 19 18
018009

1 M10x20 (SW 16) hex bolt with shim 17 O-ring

2 Compression spring with shim 18 Inner clutch disc
3 Roller 19 Outer clutch disc
4 Impeller 20 Inner clutch disc
5 Stator 21 Outer clutch disc
6 Thrust disc 22 Plate piston
7 Axial roller bearing 23 Inner piston ring, plate piston
8 Thrust disc 24 Ball bearing
9 Internal sprag race 25 Thrust disc
10 Ball bearing 26 Axial needle cage
11 Thrust disc 27 Housing disc
12 Rollers 28 Turbine wheel
13 Thrust disc 29 Outer piston ring, plate piston
14 Ball bearing 30 Cup spring
15 End shim 31 Circuit cover
16 M10x30 cylindrical screws

4149 751 606a 12

W 390 MS torque converter Special tools

Fig. Special tools Order no. Application Qty. Comments

no.

1X56 137 213 1

Lifting device
1 for turbine shaft

1X56 136 862 1

Lifting device
2 for torque converter

1X56 137 152 1

Support
3 for stator bearing

1X56 137 658 1

Counter holder
4 for unfastening and tightening screw
plug in torque converter

1X56 137 158 1

Retaining fixture
5 for unfastening and tightening M16
cylindrical screw in torque converter

4149 751 606a 13

W 390 MS torque converter Special tools

Fig. Special tools Order no. Application Qty. Comments

no.

1X56 137 130 1

Pneumatic unit
6 for seal integrity test of torque con-
verter and clutch carrier, used in con-
junction with feed bush 1X56 137
128 and forcing device1X56 137 129

1X56 137 129 1

Forcing device
7 for torque converter seal integrity test

1P46 173 831 1

Feeler gauge
8 for measuring the clutch disc clear-
ance

4149 751 606a 14

W 390 MS
torque converter

1. Removing and installing torque converter

1
1.1 Removing torque converter

1 Rotate the transmission in the swivel stand so

that the torque converter is facing upwards.
2
2 Attach counter holder 1X56 137 658 (1) to
torque converter and transmission housing and
screw in.

3 Unscrew screw plug (2).

017950

4 Screw retaining fixture 1X56 137 158 (3) into

torque converter circuit cover and tighten by
3
hand.

NOTE
Make sure rubber washer is fitted onto
retaining device thread.

NOTE 017951

In addition to the pneumatic retaining device,

ZF can also use a mechanical retaining device
1X56 136 864 in conjunction with the hex
insert 1X56 136 863.

5 Connect pneumatic unit 1X56 137 130 onto

retaining fixture 1X56 137 158. 2

6 Turn the regulator (1) anti-clockwise a few

times.

7 Open stopcock (2). The lever must be 1

horizontal.

8 Use the regulator (1) to set a pressure level of

1.5 bar.
017952

4149 751 606a 1-1

W 390 MS
torque converter

9 Insert 1/2 socket wrench extension (1) and

unfasten cylindrical screw. 1
NOTE
Use a suitably long grip. The M16 cylindrical
screw is tightened to 190 Nm in the turbine
shaft. 2

10 Close stopcock.

11 Unscrew retaining fixture 1X56 137 158 (2)

from torque converter circuit cover.

017953

12 Unscrew cylindrical screw (1) and take out

torque converter.

017954

13 Screw lifting device 1X56 136 862 (1) into

torque converter and tighten by hand. 1

14 Remove counter holder 1X56 137 658.

15 Carefully take torque converter out of trans-

mission.

NOTE
Before lifting out the torque converter
completely, raise it to just above the turbine
shaft. Then tilt the torque converter slightly so
that the oil can drain out.

017955

4149 751 606a 1-2

W 390 MS
torque converter

16 Unscrew lifting device.

17 Turn the torque converter over and remove the

shim(s) (1) from the torque converter or turbine
shaft. 1

! DANGER
Torque converter weighs approx. 50 kg. Before
removing the lifting device, secure the torque con-
verter to prevent it from rolling away.

017956

18 Remove spacer ring (2) from stator hollow

shaft.

017957

4149 751 606a 1-3

W 390 MS
torque converter

1.2 Installing torque converter

1.2.1 Measuring torque converter end float 1

1 Screw lifting device 1X56 136 862 (1) into

torque converter so that the torque
converter turbine wheel is clamped tight.

2 Turn torque converter over.

DANGER
Torque converter weighs approx. 50 kg. Secure
torque converter to prevent it from rolling away.

017958

3 Measure the distance "C" between the face end

of the spur gear and the turbine wheel.

4 Note down distance "C".

017959

5 Measure the distance "B" between the face end

of the spur gear and the face end of the internal
sprag race.

6 Note down distance "B".

017960

4149 751 606a 1-5

W 390 MS
torque converter

7 Calculate the theoretical distance "D" between

the face end of the internal sprag race and the
plane face of the shim as
follows.

CB=D
Note down distance "D".

D B
C
017961

8 Check rectangular ring (1) for damage. Replace

if necessary.

9 Align rectangular ring centrally.

NOTE
Rectangular ring has hooked ends.

10 Slide spacer ring (2) onto stator hollow shaft so

2
that there is no end float.
1

017962

11 Screw lifting device 1X56 137 213 into turbine

shaft.

12 Tighten lifting device by hand until there is no

end float on the turbine shaft.

13 Place depth gauge in recess of lifting device on

end face of turbine shaft. 1

14 Measure distance "A" between face end of

A
turbine shaft and spacer ring (1) on stator
hollow shaft.

15 Note down distance "A".

16 Unscrew lifting device from turbine shaft.

017963

4149 751 606a 1-6

W 390 MS
torque converter

17 Calculate thickness "S" of shim (1).

D A = E
Distance "E" plus the specified torque
converter end float (distance "G")
(* 0.3 to 0.4 mm) gives the required
thickness "S" of the shim (1) to be fitted.
E + 0.3 to 0.4 mm = S

Calculation example:
C = 174.7 mm D = 119.50 mm
B = 55.2 mm A = 118.30 mm
D = 119.5 mm E= 1.20 mm
*+ G= 0.35 mm
S= 1.55 mm

CAUTION
Distance "G" must be added and not subtracted
otherwise the bearings will be damaged.

Shims (OTK) 0730 005 591 are available in

thicknesses ranging from 2.6 mm to 1.0 mm,
in 0.1 to 0.3 mm steps.

NOTE
Thicker shims mean greater end float.

18 Thinly coat shim (1) with grease and affix.

19 Centre the shim. 1

20 Centre rectangular ring (2).

21 Thinly coat race of seal (arrow) with oil.

017964

4149 751 606a 1-7

W 390 MS
torque converter

22 Screw lifting fixture 1X56 136 862 into torque

converter.

23 Carefully lower torque converter so that it is

centred on the turbine shaft. Fit the torque
converter so that there is no end float.

017955

24 Loosen lifting device 1X56 136 862 by

unscrewing a few turns.

CAUTION
Take care not to damage the seal. Ensure the shim
is correctly positioned on the turbine shaft.

NOTE
The turbine shaft and stator hollow shaft splines
must mesh inside the torque converter. Rotate
the torque converter slightly if necessary. The
gear on the torque converter must also mesh
with the input gear of the primary shaft.

017965

4149 751 606a 1-8

W 390 MS
torque converter

1.2.2 Measuring torque converter installation

dimension

1 Make sure the torque converter is fitted

correctly and without any end float.

2 Measure installation distance "F" between

torque converter mounting face and
transmission mounting face.

3 Measure the distance at several points around

the circumference and calculate the average
value.

NOTE
Installation dimension "F" must be X 0.5 mm.
Ecomat transmissions can be equipped with dif- 017966

ferent types of torque converter. Distance "F"

(torque converter installation dimension) must
be one of the following installation dimensions,
depending on torque converter version.
F
Distance "F" = 81.25 mm

If installation dimension "F" is between X + 0.5

mm and X 0.5 mm, then the setting is correct.

4 If the installation dimension is less than

X 0.5 mm, fit a second spacer ring on the
stator hollow shaft.

5 If the distance is more than X + 0.5 mm,

remove the spacer ring.
017967
NOTE
The spacer ring is 1 mm thick.
CAUTION
If the distance "F" is changed by adding/removing
a spacer ring on the stator hollow shaft, the shim
on the turbine shaft must also be changed accord- 1
ingly. Otherwise the bearings will be damaged.

6 Unscrew lifting device 1X56 136 862 from

torque converter.

7 Screw M16 cylindrical screw (1) into turbine

shaft.

8 Re-check the installation dimension.

017954

4149 751 606a 1-9

W 390 MS
torque converter

9 Attach counter holder 1X56 137 658 to trans-

mission housing and bolt it to torque converter.

10 Screw retaining fixture 1X56 137 158 into

torque converter circuit cover and tighten by
hand.
2
NOTE
Ensure rubber washer is fitted onto
retaining device thread.

11 Connect pneumatic unit 1X56 137 130 onto 1

retaining fixture 1X56 137 158.

12 Turn regulator (1) anti-clockwise a few times.

13 Open stopcock. Move the lever (2) into 017952

horizontal position.

14 Use regulator (1) to set a pressure level of 1.5

bar.

15 Insert 1/2" socket range extension and tighten

hexagon socket head screw;
tightening torque: 180 - 190 Nm 3

16 Close stopcock.

17 Remove retaining fixture 1X56 137 158 (3)

from torque converter circuit cover.

017953

18 Fit new copper seal on screw plug (1).

1
19 Tighten M33x2 screw plug;
tightening torque: 190 - 210 Nm

017968

4149 751 606a 1-10

W 390 MS
torque converter

2 Dismantling and assembling torque

converter

2.1 Dismantling torque converter

1 Place torque converter on planks so that

impeller faces upwards. 1

2 Unscrew all M10x22 (SW 16) hex bolts and

washers (1) leaving only one hex bolt on each
opposite side.

3 Turn torque converter over so that impeller

faces downwards or circuit cover faces
upwards.

4 Remove two remaining hex bolts on opposite 017969

sides.

5 Attach hoisting rope to lifting device

2
1X56 136 862 (2) and lift circuit cover (3) off
impeller using hoist.

3
! DANGER
Turbine wheel may remain in circuit cover and fall
out. Therefore, only lift the circuit cover as high as
necessary and immediately lay it down close by.

017970

6 Take off turbine wheel (1).

017971

4149 751 606a 2-1

W 390 MS
torque converter

7 Take housing disc (1), axial needle cage (2) and

thrust disc (3) off stator (4).
1
CAUTION
Do not mix the bearing assemblies when installing.
The thrust and housing discs must not be mixed up
2
with any other bearing modules. Clearly mark all
parts. 3

4
8 Take stator (4) out of impeller (5).

017972

9 Take out thrust disc (6), roller bearing (7) and

thrust disc (8). 5

CAUTION 6
The thrust and housing discs must not be mixed up
with any other bearing modules. Clearly mark all
parts.

017973

4149 751 606a 2-2

W 390 MS
torque converter

2.1.1 Dismantling stator

1
1 Place stator (1) on support with collar (2)
facing downwards.

017974

2 Place suitable pressure piece (1) on internal

sprag race.

3 Press internal sprag race out of stator. 1

017975

4 Remove roller (1) from internal sprag race (2).

5 Take off thrust disc (3) from internal sprag race. 2

017976

4149 751 606a 2-3

W 390 MS
torque converter

6 Press internal sprag race (1) out of ball bearing

(2).

! DANGER
Do not clean bearings using compressed air. 1
Bearing races could come loose and damage the
bearing due to lack of lubrication.
2

017977

7 Place stator (1) on press using suitable support

(2).
3
8 Use suitable pressure piece (3) to press ball
bearing out of stator.

CAUTION
The diameter of the pressure piece must match the
outside diameter of the bearing.

2
017978

9 Remove ball bearing (1) and thrust disc (2)

from stator.
1
2

017979

4149 751 606a 2-4

W 390 MS
torque converter

2.1.2 Assembling stator

1 Insert stator on suitable support in press with

collar (2) facing upwards.

2 Insert thrust disc in stator. 1

3 Use special tool 1X56 137 152 (1) to press ball 2

bearing (3) in as far as it will go.

017980

4 Insert support 1X56 137 152 (3) into press with

hollow facing upwards.

5 Turn stator over (collar (2) facing upwards) and

place on support 1X56 137 152.

6 Insert internal sprag race (1) into stator with the 1

longer collar facing downwards and press in.
NOTE
Using support 1X56 137 152 ensures that the
internal sprag race is fitted in the 2
correct position.
3

017981

7 Insert rollers (1) in stator.

NOTE
After insertion, moderately oil the rollers and
rotate the stator several times. 1

8 Insert thrust disc (2) in stator.

017982

4149 751 606a 2-5

W 390 MS
torque converter

9 Insert support 1X56 137 152 in press and place

stator on support complete with ball bearing.

10 Place second support 1X56 137 152 (1) on ball

bearing (2).
1
11 Press ball bearing into stator until firmly home.
NOTE 2
Ensure that the hollows on both supports
1X56 137 152 are facing the stator. Using the
supports ensures that the bearing is fitted in the
correct position.

017983

4149 751 606a 2-6

W 390 MS
torque converter

2.1.3 Dismantling circuit cover

1 Unscrew 24 M10 cylindrical screws (1) from 1

circuit cover.

2 Remove O-ring (2).

017984

3 Remove end disc (3).

4 Remove inner and outer clutch discs (4) from 3

circuit cover.

NOTE
4
Compression springs with discs (5) can be
found on the last outer clutch disc.
5
5 Remove compression springs, discs (5) and last
outer clutch disc.
6
6 Take out twelve rollers (6).

017985

7 Take out cup spring (1).

017986

4149 751 606a 2-7

W 390 MS
torque converter

8 Force the ball bearing (1) off the turbine wheel

using two assembly levers.

9 Gently strike circuit cover with plastic

hammer to remove plate piston (2). 1

017987

10 Use appropriate tool (0.5 - 0.75 mm thickness)

1
to grasp inner rectangular ring (2) and carefully
take out plate piston. 2
!DANGER
Grooved edge of plate piston may have sharp edges.
Wear protective gloves.

11 At the same time slide both sides of outer rec-

tangular ring (1) in direction indicated by
arrows. Grasp protruding part of rectangular
ring and take out of annular groove.

017988

4149 751 606a 2-8

W 390 MS
torque converter

2.1.4 Assembling circuit cover

1
NOTE
Thoroughly clean all components and dry using 2
compressed air. Only use lint-free cloths to
wipe off the rectangular rings.

1 Check rectangular rings for damage and replace

if necessary.

2 Coat inner rectangular ring (2) and outer rectan-

gular ring (1) with Vaseline and insert them into
the plate piston.

NOTE
Stretch the inner rectangular ring a little before
installing so that it sits firmly in the base of 017988

groove.
3
3 If removed, use plastic hammer to drive in ball
bearing (5). 4

CAUTION 5
Insert plate piston (3) in circuit cover without tilt-
ing it. Ensure that the rectangular rings are firmly
seated in the base of the groove all the way around.
6
4 Tap around the edge of the plate piston with a
plastic hammer. Make sure that the plate piston
is correctly positioned.

5 Place cup spring (4) onto plate piston with

camber facing downwards.
017989

6 Insert twelve rollers (6) into holes around the

edge.

7 Use a straight edge to check that the outer and

inner clutch discs are flat and not distorted or
perform a visual check. Check the discs against
the end disc or a flat surface.

CAUTION
Replace any discs that are dished or corrugated.
Maximum permitted wear is 0.3 mm. Replace lined
discs that have damaged or blackened linings.
Replace inner clutch discs that have damaged tooth
flanks. Maximum permitted wear per tooth flank
is 0.2 mm.

017990

4149 751 606a 2-9

W 390 MS
torque converter

8 Insert first outer clutch disc (1) so that the holes 5

slide over the rollers. 4

9 Place four discs and four springs (2) over the 1

rollers and onto the outer clutch disc at 90
intervals.

10 Insert first inner clutch disc (3). 3

11 Insert second outer clutch disc (4) offset at an

angle to the first outer clutch disc. 2

12 Insert second inner clutch disc (5) in circuit

cover.

017991

NOTE
Insert outer clutch disc (4) so that the tooth
spaces for the springs (arrow) and bores are
above the remaining rollers. Outer clutch disc
(4) must not rest on the springs.

017992

13 Insert two M10 threaded pins (1) at angle. 1

14 Line up the holes on the end disc (2) with the

holes in the circuit cover. Fit end disc over
threaded pins and onto springs in circuit cover.

017993

4149 751 606a 2-10

W 390 MS
torque converter

15 Screw in 24 M10x30 cylindrical screws (1).

Tightening torque: 69 Nm
1
NOTE
Before tightening the hex bolts, tap the plate
piston fully home with a plastic
hammer.
2
16 Use a feeler gauge (2) to measure the play
between the last inner clutch disc and the end
disc (3) and note down as distance "A".

017994

17 Disc play (distance "A") must be between

0.6 mm and 1.2 mm.

NOTE
If the disc play is less than 0.6 mm or more than
1.2 mm, fit new outer clutch discs as necessary.
Then re-measure distance "A".

18 Turn over turbine wheel and drive spacer disc 017995

(1) into turbine wheel as far as it will go (if pre-

viously removed). 1

19 Strike spacer disc at four points around the edge

to secure it.
2
NOTE
Install spacer disc with holes facing upwards.

20 Insert rectangular ring (2) in annular groove

and hook in the open ends of the ring.

! DANGER
Rectangular ring has sharp edges. Wear protective
gloves.

017996

4149 751 606a 2-11

W 390 MS
torque converter

21 Align inner clutch discs. The discs must cover

each other.

22 Insert turbine wheel (1) in circuit cover.

CAUTION
Ensure that the teeth on the turbine wheel mesh in
the gaps on the inner clutch discs. Rotate the tur-
bine wheel back and forth until it engages. Ensure 1
that the turbine wheel is fully engaged and inserted
as far as it will go. If necessary, tap edges of inner
teeth with plastic hammer. Take care not to damage
inner clutch discs.

017997

4149 751 606a 2-12

W 390 MS
torque converter

2.1.5 Measuring axial bearing end float.

Take measurement as check
1
NOTE
Production tolerances give the specified axial
play. There are no provisions for adjusting the
axial play using shims. Measuring is for check- 2
ing purposes only.

1 Insert the axial disc (3) in the impeller (4).

2 Insert the axial roller bearing (2). 3

3 Insert the axial disc (1). 4

017973

4 Insert the stator (5) in the impeller with the

longer collar of the freewheel inner ring facing 1
downwards.

5 Fit the axial disc (3) on the shorter collar of the

2
freewheel inner ring (4) on the stator.

6 Fit the axial needle cage (2). 3

7 Fit the housing disc (1).

4

017972

8 Place the measuring plates (3) on the mating 3

face of the impeller. 2
9 Fit the measuring strip (2).

10 Place the depth gauge on the measuring strip

and measure the distance "A" between the mea-
suring strip and the impeller mating face (1).
Note down distance "A".
1
NOTE
The measuring strip must not lie on the stator.

017998

4149 751 606a 2-13

W 390 MS
torque converter

11 Move the depth gauge to the middle.

12 Measure the distance "B" between the measur-

ing strip and the front face of the housing disc
(1).

13 Note down distance "B" and subtract distance

"A" from it.

B - A = Distance "C"

14 Mount the measuring setup on the circuit cover 017999

mating face.

NOTE
Do not insert an O-ring in the circuit cover for
the purpose of measuring.

15 Use the depth gauge to determine the distance

"D" between the measuring strip and the mating
face of the circuit cover (1). 1

16 Note down distance "D".

17 Determine the distance "E" between the mea-

suring strip and the point of contact with the
shim (2).

18 Note down distance "E" and subtract it from 018000

distance "D".

D - E = Distance "F"

Subtract distance "F" from distance "C". 2

C - F = Distance "G"

Distance "G" = axial play of the axial bearing

Specified axial play of the axial bearing

= 0.0 to 1.1 mm

NOTE
Distance "G" must be within the specified axial
play of 0.0 to 1.1 mm.
018001

4149 751 606a 2-14

W 390 MS
torque converter

2.2 Assembling torque converter

1 Insert housing disc (1) in the turbine wheel with

chamfered side facing turbine wheel.
1

2 Insert axial needle cage (2) and thrust disc (3)

in turbine wheel.
2

018002

3 Insert stator (1) in turbine wheel with short

collar of internal sprag race facing the turbine
wheel. 1

NOTE 2
Coat all bearings with oil before installation.

4 Place thrust disc (2) on long collar of

internal sprag race with chamfered side facing
stator.
3

5 Fit roller bearing (3).

4
6 Fit thrust disc (4).

018003

7 Insert O-ring (2).

1
8 Screw two M10 threaded pins (1) opposite one
another in circuit cover flange.

018004

4149 751 606a 2-15

W 390 MS
torque converter

9 Place impeller (1) on circuit cover. 2

10 Screw in two of the M10x22 hex bolts
(SW 16) with washers.

11 Unscrew M10 threaded pins (2).

12 Screw in remaining M10x22 hex bolts.

018005

13 Tighten M10x22 hex bolts (SW16),

Tightening torque: 65 Nm

018006

14 Check end float of internal sprag race (1).

15 Use both hands to grasp inside of internal sprag

race and move in axial direction. End float must
be palpable.
1

017956

4149 751 606a 2-16

W 390 MS
torque converter

3 Checking seal integrity of torque converter

1 Insert forcing device 1X56 137 129 (1) into

1
torque converter at spur gear end.

018007

2 Screw lock nut (2) onto forcing device.

2
!DANGER
Torque converter weighs approx. 50 kg.

018008

3 Lower torque converter into basin using

lifting gear so that forcing device is
underwater. 1
4 Connect pneumatic unit 1X56 137 130 to
forcing device.

CAUTION
The water in the basin must contain 1 part
antifreeze to 120 parts water.
Water temperature = 20C.

003 127
003127

4149 751 606a 3-1

W 390 MS
torque converter

5 Turn regulator (1) anti-clockwise

1
6 Open stopcock (2).
2
7 Use regulator (1) to set a pressure level of
2.5 bar.

CAUTION
Torque converter must be absolutely leak-tight.

018010

8 Close pneumatic device 1X56 137 130 and

remove from forcing device 1X56 137 129.

9 Lift torque converter out of basin using

1
lifting gear and lay to one side on work
surface.

10 Detach torque converter from lifting gear and

turn over.

11 Unscrew lock nut (1).

018008

12 Place torque converter on circuit cover and

remove forcing device 1X56 137 129 (2) from
torque converter.
NOTE
Dry torque converter using compressed air. 2
Lightly coat spur gear with oil.

018007

4149 751 606a 3-2