Order No. 5871 162 002 E ZF - POWERSHIFT TRANSMISSION WG-180 WG-200 ZF Passau GmbH Donaustr. 25 - 71 D-94 034 Passau05.10.95WORKSHOP MANUAL FOR ZF-POWERSHIFT TRANSMISSIONS WG-180 AND WG-200 In this Workshop Manual, the Disassembly and Reassembly of several Transmission Versions as well as Assemblies are treated. ‘The technical development of the product and the extension of the possible Versions may require varying steps, which can be carried out without great difficulty by trained personnel, consulting the Perspective Illustrations of the corresponding Spare Parts Lists. Indications regarding Description, Installation, Instructions, Operating and Maintenance, see catibeniiog Operating Instructions! ZF Passau GmbH Donaustr. 25 - 71 D-94 034 Passau Abt.: ASTDM / Section : ASTDM ‘Nachdruck auch auszugsweise ohne dic Genehimigung der ZF Passou GribH nicht gestatct! ‘Copyright ZF Passau GmbH! ‘Copying even partially not permitted! ‘Reproduction meme par extrait est interdite! ‘Tectnische Andeningen vorbehalten! With the reserve of technical modifications! ‘Sous reserve de modification techniquest ‘Ausgabe / Edition : 1994/02PREFACE ‘This documentation has been developped for the skilled Serviceman, trained by the Zahnradfabrik Passau for the Repair and Maintenance operations on ZF-Units. ‘Treated is a ZF-Serial product according to the design stage of the date of Edition. However, due to further technical developments of the product, the repair of the unit at your disposal could require differents steps as well as other adjustment and testing specifications. Therefore, we recommend to commit your ZF-Product to Masters and to Service-men, whose ‘practical and theoretical training is constantly completed to the actual situation in our Training School. The Service Stations, established by the Zahnradfabrik Friedrichshafen all over the world, offer you: J. Constantly trained personnel 2. Prescribed installations, e.g. Special Tools 3. Genuine ZF-Spare Parts according to the latest phase of development Here, all operations are carried out for you with utmost care and realibity. Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual contractual conditions, by the ZF-Warranty, Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-cxpenditures eventually arising from it, are excluded from this contractual responsibility, This applies also in case of a renouncement of Genuine ZF-Spare Parts. Zahoradfabrik Passau GmbH Service Department O01GENERAL WORKING INSTRUCTIONS During all operations, pay attention to cleanliness and. skilled working. ‘Therefore, Transmissions, removed from the vehicle, must be cleaned prior to open them. We assume that the Special Tools, specified by ZF, will be used. ‘The Special Tools have a 10-digit Subject-No, and are availabe from ZF-Passau. After the disassembly, all components must be cleaned, especially comers, cavities and recesses of housing and covers. The old sealing compound must be carefally removed. Check Inbricating holes, grooves and pipes for free passage. They must be free of residues, foreign material or protective compounds. The latter refers expecially to mew parts. Parts which have been inevitably damaged in a disassembly operation, must be generally replaced by new ones, e.g. : rotary seal rings, O-Rings, U-Section rings, cap boots, protective caps etc... Components such as roller bearings, thrust washers, synchronizing parts ete. which are subject to normal wear in automotive operation, must be checked by the skilled Serviceman, ‘He will decide if the parts can be reused. For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used. Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in a vessel filled with oil, which is then heated with the flame. In this way, damage to the bearings could be avoided. Ball bearings, covers, flanges and parts like that must be heated to about 90° to 100° C. Hot-mounted parts must be reset after cooling in order to assure a proper contact, Before pressing shafts, bearings etc. in position, both parts must be lubricated. During the reassembly, all specified adjustment values, testing specifications and torque limits must be respected. After the repait, ZF-Units are filled up with oil. ‘The procedure and the permitted oil qualities can be taken from the Operator's Manual, resp. from the Lubrication Instructions and the corresponding List of Lubricants. ‘The Lists of Lubricants are available at all ZF-Service Stations. Afler the oil filling, the oil level phigs and oil drain phugs must be tightened to th specified torque limits, oonIMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY In principle, Repairers of ZF-Units are themselves responsible for the labour safety. The observance of all valid Safety Regulations and Legal Rules is a precondition to prevent damage to individuals and products during the Maintenance and Repair operations, Refore starting the work, the Repairers have to make themselves familiar with these Regulatisons. The proper Repair of these ZF-Products requires especially trained personnel. ‘The Repairer himself is obliged to provide for the training. 003Hinmsis; Uingsnbezogeoe Malle in kg'm; _‘flichanbezogane Malle in vim? Note: linear density in kg/m; areal density in tn? Moin; Density Kinonre 6a hpi Density superticielle en vind Tip=981N 102 pm = = 1 Nas TPS= 07333 KW 1 KW =1,36 PS Tia = 91 Ne oz ata = 1,02 eprom = Uber = 750 tow 0081,356 Nm ( 0,138 kpm ) Lkg fem 1 bar ( 1,02 kp/em? ) 0,070 bar ( 0,071 kp/cm? ) Tin ( inch) 2,205 Ib ( pounds ) 7,233 ibf x ft ( pound force foot) LIbfx ft ( pound force foot ) 5,560 Ib/ in ( pound per inch ) 14,233 psi (pound force per squar inch Ibffin2 ) 1 psi( Ibfin? ) 0,264 Gallon ( Imp. ) 1Galllon ( Imp. ) 0,220 Gallon ( US ) 1 Gallon ( US ) 1 Mile ( Landmeile ) 432° F ( Fahrenheit ) 273,15 Kelvin osTORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZFSTANDARDS | as for phosphates outs. Tighten by hand! ‘Torque limits, of not exspecially, cam be taken from the following list: Metric 1S0-Standard Thread DIN 13, Page 13, hao Maa Mae 670, 960 1120 Ma? 7000 1400 1650 2250 1850 2350 3300 3900 Moe 3000 4300 3100 Metric ISO-Fine Tread DIN 13, Page 13 83 109, 129 Mex 2435 36, 8 Mox1 36, 3 a 10x 1 EB 76, © IM 10x. a R 4 IM 12x 123, 7 135 150 a 122 145 Misx 15 1s 200 25 M16x 15 205 300 360 Mie 15 310 Ho 520 IM 18x 2 290 20 490 IM 20x 1.5 430 620 720 IM 22% 1.5 380 820 360 IMaax 15 760 1090 1270 Maan? 730 1040 1220 IM27x 1.5 10 1580 1850 [Marx 2 1070 1500 1800 IM30x 15 1540 2190 2560) [Ma0x2 1490 2120) 2430. [M33 x15 2050 2920) 3420) [M33x2 72000 72800, 3300 IM36x 1,5 72680 3820 ‘470 IM 36x3, 72500, 3500 3100, [o39% 15 3430 4590 3720 39x 3 3200 3600) 3300) 0.06INSCRIPTIONS ON A ZF-MODEL IDENTIFICATION PLATE FOR ZF-HYDROMEDIA- REVERSING-TRANSMISSIONS: 1 = Gearbox type 2 = Gearbox.No, ZF-Parts List-No, ‘Total ratio of the Gearbox Value for the control pressure ‘ZF-Parts List-No. of the Torque Converter ‘Type of the ZF-Torque Converter vomse eeena (6) Zahnradfabrik Passau @ (ras teense] NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine 2F-Spare Parts, please indicate: Gearbox type Serial-No. | See Model Identification Plate! ZF-Parts List-No. Mark and type of vehicle Denomination of the spare part Spare parts-No. Way of transport see eens When all of the above required indications ere considered, errors in the delivery of spare part orders can be avoided!Optional versions and additional equipment for the transmissions of the WG range 1 Converter hausing for direct in- st 2 Torque converter 9 Lock-up elirtch 4 Cover for separate installation 5 Retarder '@ HN 500 converter transmission T Input flange (for separate instal- lation) @ Contre distance input’ output shatis 9 Axle disconnect unit 10 Parking brake 11. Speedometer connection 12 Inter-axle ditterential 13 Axle deive, flange-mounted 14 Multi-dise clutch for 4.5 and 6-speed version 18 Emergency steering pump 16 PTO unit, engine driven 17 Transmission contre! 18 Steering column switch SG 4/ sc6 19 Console switch $@ 4/56 6 20 Rotary reversing switch OW 1 21 Automatic control unit EST 2 22 Inching valve 23 Dual pressure control vaive 24 Pressure cut-out 25 Micra-tate 26 Transmission connection for ‘separate filter instaitation 27 Converter charge andi shitt pump(Read Tramunishns Division ‘Torque converter transmissions for off-road vehicles and ‘machinery (construction plant, special vehicles, lift trucks) List of Lubricants TE-ML 03 Engine ots Wo sor 1/88 85 API €D/ CE/ CF/SE/SG wa 100 (MIL-L-2108 C)-D/-8 WG 120y 121 MIL-L-46132 C/-D/-E WG 150) 151 + SAE IOW (WG 180) 181 + SAB 10W20 |W 200) 201 + SAE IOW-40 WG 250 = SAE IS W.40. wo 6s = SAE 20W.20 N50 Pw ASH (I) ‘For commercial products see overleaf Pw2sH Pw Is Automatic Transmission Fluids (ATF) only at ambient HSC 210 ‘emperatures below 10 °C = engi = Engine oils SAE 20W.20 asc SAE 15 W-40 oc SAE 10W, 10.W-30, 10.640 °C - ATF -10°e he minimrn oil temperate for starting the vehicle moving ean be achieved at least 20 minutes” warm-ap in "Nectal” senting + preheating At greasing poiews, use a rmbi-purpose grease with the following propertica: lithium s04p, trop point above 170°C, NLGH Class 2. ‘The grease mit be ant-conrosive, water-tesitant and walk erable Note to lubricant suppliers: Pleaic inform ZF immediately of any changes tothe composition or trade names of approved product, and of differences in. quality between Germany and other countries. ‘This lst ean be obtained through any ZF Telephone (08:51) 498-0 After Sales Service pot. Telex $7849 zp Telefax (08:51) 45.340 0.09 1208754 1010192‘oils API CD/CEICRISE/SG, Engine oils API CD/CE/CEISFISG, MIL-L-2104 C/-D/-E, MIL-L-46182 C/-D/-E MIL-L.2104 C/.D/E, MILAL-46182 C-DIE soc net can CTNERDOr rs common cusorease ‘Sineao so RRO BASE Seinnce naar otemaberyes roe ena lc career, Dcrulneri utca KORTRENAASIYY. Bonde ‘tienes soe ems sk areas ova ane Ne mmosys ancy ‘Srnoecsnce GinimiCouna Coke sTeroaeo Saneee srmon FO mo fog mrecaps: wcen ‘Soo tes roe ‘soreness fiends oe ream MIR Neiicramncoorey acrance Forman na Easba cima count, Mtisnamescwest marcsa fo seutvonses worms Succ. zane Sirens 2. iim: eukomasria Eicowornsoner a. ‘Spec thane oes Bouma tee (aoe tecren sev tan karo ausorasenane Som womsan orice Sratacraar Mearnne Ra Anetta rine Mswran NowagsioL ou mice coma KeLND RenrasiOULTRALLR ‘anon saat ‘Sub runbansn omenot KGrumacod Waasonome koe tures saeco ‘Soncun sexe ‘Sear hour sa 5008 Soronon sau ‘Sec an ace Sec roma too acomuce ‘ioe incr sce ‘Son kbanai ne ENE ‘Siirzeid wore oa. te Rowan ernaneano AE Nowab aNcMEND Siw worexmec 10. form. ane Nominee Aa WADE Neatsroc i W039 FERS On FT SONS ines AL EOAADE TORO, 2 0.10J. ELECTRO-HYDRAULIC GEARBOX CONTROL ATTENTION : In case of malfunctions of the Transmission because of a defective gearbox control, we fecommend the replacement of the complete gearbox control. The pressure-control curve of the replacement-gearbox control (see corresponding Spare Parts List} has been accordingly adapted to the Transmission Version, resp. to the Vehicle type. Modifications concerning the pressure-control curve may not be carried out without agree ment of ZF. Therefore, the repair of gearbox control units should be carried out by ZF- Service stations only. The relative shop equipment of our Service stations (gearbox control resp. trans test benches) as well as constantly trained personnel ensure a professional repair. The following Disassembly and Reassembly Instructions (Page 1.01 - 1.73) will therefore be useful only a3 an Information for ZF-Service stations as well as for the Manufacturer of the vehicle, which are disposing of the required workshop equipment and especially trained personnel. ion 101Note. the ntrol: Di Pressuré-control curve gear case = Pressure in bar {= Time in seconds pl = Modulation start p2 = Modulation PP = Modklstion start ely in. ‘with 2-ctage pressure control valve ATTENTION: curve is different according to the ‘Transmission Version, resp. the vehicle type and will be 1 ‘The pressure-control adjusted by means of corresponding shims and diaphragms (optional)!Note: In the following Disassembly and Reassembly Instructions are three different gearbox control Variants treated. 12 Alumisium sand-casting gearbox control 13° Aluminium die-cast gearbox control with WK-Valve. With the help of the following Figures, the coordination of the single gearber control variants can be visually identified because of the different casting contours! 1.1 Cast-iron gearbax control i Qa merino freee reser ‘antral pressure) = Clutch KV = Cwich KR = Clutch Kt ‘Clutch K2 se4aean & ‘Clutch K3 = Clutch K4 1.2 Aluminium sand-casting gearbox control (eg. 4 magnets) | Central measuring point for system pressure (Gantrol pressure) ‘Clutch KV Clutch KR ‘Clutch KR {in case of Ssmagnet Version) Clutch Ki ‘Clutch K2 Chuteh KS Seuagae a 1 Clutch Ka Clutch Ke (in case of S-magnet Version) 3 13 Aluminium die-cast gearbox control = Central measuring point for system pressure \ontrol pressure) Clutch KR (Cluteh Kt Clutch K2 Clutch K3 Clutch Ki 6s 3 ss 6 7 8 oO. Furthermore, the single gearbox contro! units can include WK-Valve, 2-stage pressure control valve as latte. Seago (olr fr sesbox cated 12) Different steps resulting from this, can be carried out without great difficulty by qualified personnel, Consultag the Perspective Ilustraicas in the corresponding Spare Parts Lint1.1 CAST-IRON GEARBOX CONTROL 1.1.1 Version 1: Standard Version (without WK and 2-stage pressure contro! valve) 1.11.1 DISASSEMBLY \te_shift-control and_ channel plate gear case (Figure |... 3). Loosen socket head screws, install two adjus~ ting screws (Arrows) and remove shift-control housing. Now, remove gaskets and intermediate plate. (3) Adjusting screws (M3) 5870 204 O11 Now, remove gaskets and intermediate plate. Remove delivery lines. Loosen socket head screws and separate chan- nel plate as well as gaskets and intermediate plate from the gear case. 1.05Relax spring clip and remove cover. Pull off cable shoes, loosen the socket head screws and remove solenoid valves. Remove components, see Figure on the left! Loosen two hex. head screws and fix shift- control housing provisionally, using Special Tool (5). Now, loosen the remaining hex. head screws and separate cover (is spring-loaded) from the valve body by uniform loosening of the ruts (5S). (s) ('S) Adjusting screws (M3) 5870 204 036 with nu it (S) Adjusting screws (M6) 5870 204 049 with nutRemove components, see Figure on the right Remove stop plates (Arrows) and demount de- tent blocks. NOTE + The use of two spools in order to fix the de- tent block provisionally axially (Figure 10), avoids the tilting of the detent blocks, thus facilitating the disassembly { 1.0713 Jot.1.2 REASSEMBLY see also Hlustrated Tables, Page 1.1% NOTE = ‘Check all components for damage and renew if necessary ! Check free travel of the moving parts in ‘the housing prior to the installation ! Spools can be exchanged individually ! ‘Oil components prior to the reassembly ! Introduce detent blocks (I and 2) into the bores and fix them by means of stop plates G and 4), Install stop plate (5). NOTE : Pay attention to the installation position of the various stop plates, see Figure on the left IIs 2= {Lg = 88,6 mm) ae 8 = 520 mm) 4 = Disk (optional) 3 = Spacer 6 = Spool 7 = Sleeve 8 = Spool 9 = Spring = 81,7 mm) 10 = Spool 11 = Spool 12 = Spring (Ly = 65,4 mm) 13 = Spring (8 = 72,3 mm) 1% = Spool (total length 86,0 mm) NOTE = L = Length of the unloaded spring ! ps (control pressure) is determined by the disk ‘(@)! Pay attention to the General Instructions, Page 1.01 1.031 Install two adjusting screws (5 ) and mount flat gasket. Place cover against shoulder, using nuts ( 5 ). Now, fasten cover by means of screws. Torque limit, (M3/8-2) 33m (S ) Adjusting screws (M5) 5870 204 036 ‘with nut (CS) Adjusting screws (M6) 5870 20% 089 ‘with nut Install_ component 1 = Valve body 2 = Spring (L, = 72,5 mm) 3 = Spool G control surfaces) 4% = Spring (Ly = 72,5 mm) 3 = Spool G contro! surfaces) & = Spring (L, = 72,5 mm) 7 = Spool (total length 72,0 mm) & = Detent block G pieces)Preload detent block and install solenoid valve. Install remaining solenoid valves accordingly . NOTE Employ new O-Rings for solenoid valves ! Pay attention to the radial installation posi- tion of the solenoid valves, see Figure 21 ! Install cable harness (mount new gaskets), fasten ground cable and connect solenoid valves (Figure 20). NOTE = Pay attention to the location of the plug. nose, see Arrow/Figure 21 ! Mount new O-Ring (164,2 x 5,7) and fix co- ver by means of clamping collar.Pre-assemble channel plate (Figure 23 and 24) NOTE : According to the gearshift Nersions different The following ly Instruction is trea~ ting the Standard Version (with control dia~ phragm for the backfeed) ! Wet thread of contro! diaphragm with Loctite (Type-No. 270), install contro! diaphragm (Po- sition, see Arrow 1), and secure it additionally by means of center punch. Now, clean diaphragm from Loctite residues by means of compressed air. Install diaphragm for the backfeed (Position, see Arrow 2) accordingly. wan ‘thread plug (3) with Loctite (Type-No. 70) new sealing ring for connecting plug (0) and screw plug (Position, see Arrow 5), and install them. Insert the two check valves (composed of balls and springs) in the channel plate. Attach channel and control ra Install housing gasket. NOTE : Pay attention to the different gaskets, see Fi- gure 25 and 26 | (S) Adjusting screws (M3) 5870 204 O11 1awaz Install intermediate plate and 2nd gasket. ‘Assemble channel plate and fasten it by means of socket head screws. Torque limit (M8/8.8) 23.Nm NOTE : Pay attention to a correct position of the ball seat valves ! Pay attention to the position of the various screws, see corresponding Spare Parts List ! Install intermediate plate and 2nd gasket.Place gearbox control assembly der and fasten ir by svare ad docket band screws. Torque limit (M8/8_8) 23Nm NOTE : Pay attention to the position of the different screws (lengths) 1 soe acta eta (Gee Arrows) as! install them a ric pwad aalon'r toee pes enact lustrations in the corresponding Spare Parts List 1 1.13course | se aanertyo ted wot vu momen 64 ‘ober i yp ttm ee oxen ANGIE ne EH BSA12 ALUMINIUM SAND-CASTING GEARBOX CONTROL 1.2.1 Yersion 1: With 4 Solenoid valves —— ~ and attached 2-stage pressure control valve 1.2.1.1 DISASSEMBLY Remove delivery line. (S) Adjusting screws (M8) 5870 204 011 = Relax spring clip and remove cover. Pull off cable shoes and remove cable harness. ‘Loosen socket head screws and remove sole- noid valves. Remove components, see Figure on the right ! 17Loosen two socket head screws and fix shift- Now, loosen the remaining socket head screws and separate shift-contro! housing (is from the valve body by uni- form loosening of the nuts (S ). (5) Adjusting screws (M5) 5870 208 036 (s) Katine erowe (M6) 5870 208 049 Dismantle pressure control valve. Remove stop fag (Arrows) and demount detent blocks (2x).(NOTE Check all components for damage and renew ‘if necessary ! ‘Check free travel of the moving parts in the ‘housing prior to the installation | Spools can be exchanged i Gil companents peloe to the reassembly I Close the bores by means of balls (8 pieces # 4,50 mm). Introduce detent blocks (1 and 2) into the bo- res and fix them by means of stop plates (3 and 4). Install detent block (5). NOTE : Pay attention to the installation position | Install components 1 = Spool (total length = 86,00 mm) 2 = Spring L, = 53,40 mm) = Length of the unloaded spring 19(optional) (L, = 38,00 mm) (18 = 65,40 mm) p2 is determined by the disk § (pay attention to Notes, Page 1.01 .. 1.03)! Pressure control valve : Install compenents: 1 = Spool 2 = Spring (L,, = 132,40 mm) 3 = Spring 2 = 76,70 mn) 4 = Spool ‘Control pressure valve : Install components. Spring (Ly = 78,60 mm) Spring Ly = 65,40 mm) Disk(s) (« irical value s = ) Disk(s) tenukial ake + «3.00 mn Wet thread of diaphragm with Loctite (Type No. 270) ! A tl Is determined by the diaphragm (pay attention to Notes, Page 1.01 ... 1.03)!its | ‘Compression. spring (L, = 29,90 mm) Seat Disk (s = 2,5 mm/empirical value) ‘Spring (L, = 70,90 mm) = Screw plug (mount new O-Ring) won Raueun— Ce pin (4) 1" 3 is determined by the disk(s) 6a xy attention to Notes, Page 1.01 a 1.03) I Close the bore by means of ball (@ 5 mm), see Arrow | Install components and fix them by means of socket head screws and flat washers (Figure 34 and 55). 1 = Gasket S 3 Avex : aa i a7 5 6 7 6 B= plug. HG sa 413 is determined by the ring (3) {pay attention to Notes, Page 1.01 ... 1.03) 1 Torque limit (5/88) 3,5 Nm (CS) Adjusting screws (M3) 5870 204 036 ‘with nut (S) Adjusting screws (M6) 5870 208 049 with nut 1.21Pay attention to the installation position of the components, see Figure 56 Torque limit (M5/8.8) 5,5.Nm Insert the solenoid valves and fix them by means of retaining plate and socket head screws. Torque limit (M5/8-8) 3,3 Nm NOTE Pay attention to the radial installation posi- tion of the solenoid valves, see Figure 59 ! Pay attention to the location of the plug nose, see Arrow ! 1.22Connect solenoid valves according to the I- justration on the right. Mount new O-Ring (1642 x 5,7 mm), see ihren and fix cover eae _ Cara ping collar. Intall delivery line 1, control pressure sender 2 (according to the Version) as well as screw plug. NOTE = Mount new sealing rings and O-Rings ! Mow new sealing ings and ORIN of the corresponding Spare Parts List ! Pre-assemble channel plate (Figure 62 .. 6) + NOTE = According to the gearshift Version, different channel plate variants are possible ! Pay atten tion to the Perspective Illustration of the cor- Parts List The Reassembly Instruction is trea- following ting the Version with for the back- feed (without control aiaphery e a T Wet thread of diaphragm with Loctite (Type No. 270), install diaphragm (Position, see Ar- rew 1) and secure it additionally by means of center punch. Now, clean diaphragm from Loctite residues by means of Wotall thread plug (Pasition, see Arrow 2) ne- cordingly. 1.231.28 eee Plea CD ian acres peg NOTE = Mount new O-Rings ! Attach channel _plate_and control igure 65... 68) = eae eee NOTE : Pay attention to the installation position of ‘the components, see corresponding Spare Parts List ! Install two adjusting screws. Assemble housing gasket, intermediate plate and gasket. (CS) Adjusting screws (M8) 5870 20% 011 ‘Assemble channel plate and fasten it by means of socket head screws. Torque Limit 20 Nm NOTE + Pay attention to the installation position of the different socket head screws, see cor responding Spare Parts List !Assemble Ist gasket, intermediate plate and and gasket. NOTE = Pay attention to the various gaskets, see cor- responding Spare Parts List ! contact is obtained and fasten it by means of hex. head screws (mount flat washers). Torque limit 20 Nm Install delivery lines according to the Ilustra~ tion in the Spare Parts List ! NOTE = Mount new sealing rings !vOHIM2axa,| JNOd sauTOIe61 {90 Std qos 94 suo; yUaSMTT} $97 UBES@p 849 40J Buypula yOu ove suo!qeagsn| TT \PHIBUTAIeA UST Gunayussny ap Ing pUrS UBoURPE TARY 10 ~ 1.26 -vopmapea,1 mod sauporetyoa seb wuor ou suoqesram £27 ubysap xn 20} Gugeuya row ase ope Lonnie Woe GUNMAN #IB 4D) PE abmpHeR 8) > Lar -1.2.2 Version Il: With 5 Solenoid valves and attached WK-Valve ‘1.2.2.1 DISASSEMBLY Relax spring clip and remove cover. Pull off cable shoes. ‘Loosen socket head screws and remove sole~ noid valves. 1.29WK-Valve = Removie components. Loosen two socket head screws and fix shift- control housing provisionally, using a Special Tool (5 ). Now, loosen the remaining socket head screws and separate shift-control housing (is spring-loaded) from the valve body by uni- form loosening of the nuts (5 ). ('S) Adjusting screws (M5) 5870 209 036 with nut (CS) Adjusting screws (M6) 5870 203 049 ‘with nut Remove components. Remove stop plates (see Arrows) and de- mount the remaining components.1.2.2.2 REASSEMBLY ‘see also Mlusirated Tables, Page 1.35 iz OTE = Check all components fer damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Close the bores by means of balls (10 pieces 9 4,50 mm) ! Introduce detent block 1 and fix it by means of the stop plate 4. Install subsequently spool 2 and spring 3 (Lo = 51,3 mm), and fix them by means of the stop te 5. Install spool 6, spring 7 (Le = 33, mm) and detent block 8, and fix them by means of the Pay attention to the installation position of the different stop plates, see Figure on the 1 = Spring AL, = 53,40 mm) | Spool Disk(s) (optional) (L, = 38,00 mm) 65,80 mm) ree z TE. = p2 is determined by the disk 4 (pay attention to Notes, Page 1.01 ... 1.03) ! 131a7 Fe 1s 2- tional) 3s IL, = 76,70 mm) & = Spring (C3 = 132,40 mm) 3 = Spool NOTE : 1 is determined by the disk 2 attention to Notes, Page 1.01 ... 1.03) 1 Control valve : Install components. 1 = Spring (L, = 65,40 mm) 2 = Spring (13 = 78,60 mm) 3 = Disk(s) optional) i = Disk(s) (optional) 6 = Sleeve NOTE = ps is determined by the disks 3 and 4 (pay attention to Notes, Page 1.01 ... 1.03) ! Pre-assemble and attach shift-control_hou- sing igure 89... 92): 1 = Ball ene) 2 > Diaphn tional) 3s oem 7.00 mm) NOTE + Secure diaphragm by means of Loctite (Type No. 270) Now, clean diaphragm from Loctite residues means of com air! 12 (Modulation time-WK) is determined by the diaphragm 2 (pay attention to Notes, Page 1.01 ... 1.03)! (3) Adjusting screws (M5) 5870 208 036 with nut (5) Adjusting screws (M6) 5870 204 069 with nutPull shift-control housing by means of threa- ded bushings (5 ) against shoulder. Now, fasten housing by means od socket head screws. Torque limit (M5/8.8) 3,3 Nm (S) Adjusting screws (M3) 5870 200 036 with nut (S) Adjusting screws (M6) 5870 203 049 with nut Install components : Shift-control housing, O-Ring Solenoid valve Socket head screws (with spring washer) Spring (L, = 53,40 mm) Disk(s) (optional) Spool Screw plug (with O-Ring) : lt P init: ie NA WRN enw wee j p2 is determined by the disk 6 {pay attention to Notes, Page 1.01 ... 1.03) £ Install components = 1 = Shift-control housing 2 = Spring (L, = 51,30 mm) 3 4 = Spool 5 = Spring (Lo = 37,10 mm) 6 = Spool fixing Ceetaining pas plate and socket head screw) 7 = Spring ‘= 53,40 mm) & = Spool 9 = Retaining plate ai socket head screw 10 = Solenoid valves (5x) NOTE + Pay attention to the installation position of the valves, see Figure 95 Install cable harness. NOTE = Mount new gaskets ! Pay attention to the location of the plug nose see Arrow ! 1.33Connect solenoid valves according to the Il- lustration on the left. Mount new O-Ring (1642 x 3,7) and fix co- ver by means of clamping collar. Install screw plugs as well as control pres~ sure sender (according to the Ver: NOTE : ‘The Reassembly of the channel plate as well as the attachment of the gearbox control treated on Page 1.23 ww» 1.25 ! Pay attention to the Perspective Illustration of the corresponding Spare Parts List ! (8) Adjusting screws (M8) 5870 204 O11woyynoaxa, | anod saujoqe6y qo sed ywor au su0y uBps2p 24) 40) Saypune, you ase1.3. ALUMINIUM DIE-CAST GEARBOX CONTROL ——~— 1.3.1 Version I: With WK-Valve 1.3.1.1 DISASSEMBLY (5) Adjusting screws 9870 205 O11 Relax spring clip and remove cover. Pull off the cable shoes, loosen socket head screws and remove cable harness. Loosen socket head screws and demount sole- noid valves. 1.39Remove components, see Figure on the left! Remove and dismantle WK-Valve + Loosen socket head screws and disassemble solenoid valve. Separate WK-Shift-control housing from the valve body and dismantle it, see Figure on ‘the left 1 Loosen two socket head screws and fix the shift-control housing provisionally, using a ‘Special Too! (5 ). Now, loosen the remaining socket head screws and separate cover (is spring: from the valve body by uniform loosening of the nuts (S ). (3) Adjusting screws (M6) 5870 204 089 with nutRemove components, see Figure on the Remove stop plate and demount spring as well ‘as spool. NOTE: Installation position of the stop plate, see Ar- row | Remove diaphragm and check valves.1.42 1.3.1.2 REASSEMBLY see also Illustrated Tab! 1.49 NOTE ‘Checit all components for damage end renew if necessary ! Check free travel of the moving parts in ©il components prior to the reassembly ! new O-Rings for all screw plugs (8 and install them. Install check valves and diaphragm (optional ). 3 TE mt new O-Rings | fen O-Ring 6 x 1,5 mm (Arrow) with Greses on thatend face of the aphvag diaphragm ~ makes the easier f reassembly Ue oi ll sole grease forthe reasen- 241 is determined by the diaphragm (pay attention to Notes, Page 1.01 ... 1.03)! ‘Torque Limit : Screw plug MIOx1 20.Nm Screw plug MI8x1,5 35 Nm Diaphragm 20 NmControl pressure valve = Install components. 1 = Spring WL, = 96,20 min) 2 = Disk(s) (optional) 3 = Spool NOTE: ps is determined by the disk Gur Sines Rawe Page: 101 we 1.03) 1 Pressure control valve = ents. ‘Control spool ‘Spring, (L, = 124,10 mm) Spring (3 = 77,10 mm) Disk(s) (optional) Displacement spool Install compons ween Install disk 4, with the countersinking facing the compressison spring ! 1 is determined by the disk 5 (pay attention to Notes, Pages 1.01. 1.03) | Reversing valve : Install components. 1 = Reversing spool 2 = Speing (1, = 56:30 min) Control KY: Install components. 1 = Spool (total length = 55,50 mm) 2 = Spring (1, = 51,30 mm) 183 4Install two adjusting screws (5) and assem= ble flat gasket (Arrow). Now, pull cover against shoulder, using nuts CS} and fix it provisionally by means of ae head screws ( pieces, see Figure (CS) Adjusting screws (Mé) 5870 204 089 with nut | Shift-control housing O-Ring Screw plug Disks (optional) Spring (1, = 53,40 mm) Deiat block (spring guide) SN Awe ene = Connecting piece NOTE: Install detent block 7 with the countersin- ! king p2 is determined by the disk 5 {pay attention t0 Notes, Page 1.01... 1.03 f Torque limit (M6/8.3) 9,5 Nm (3) Adjusting screws (M6) 5470 20% 049 with nut Mount new O-Rings (Arrows) and fasten so~ Jenoid valve by means of socket head screws (mount flat washers). Torque limit (NM5/8.8) 5,5 NmIntroduce control spool (K4/KR) and compres sion spring (Lo = 31,30 mm), and fix them by means of stop plate. NOTE : Position of the stop plate, see Arrow 1 = Spring (L, = 51,39 mm) Control spool K4/KR Spring, (L, = 51,30 mm) Control spool K1/K2/K3 ene woue (Lo = 37,10 mm) iConnect solenoid valves according to the Figure on the left. Mount new O-Ring (Arrow) and fix cover by means of clamping collar. Pre-assemble and attach channel 126 ou» 129) Mount connecting pipe (1) and screw plug. (2. Install two adjusting screws and assemble housing gasket. NOTE = Pay attention to the different gaskets, see Figure 127 and 128 (CS) Adjusting screws (M3) 5870 204 O11Install intermediate plate and 2nd gasket. Assemble channel plate and fasten by means of socket head screws (mount flat washers). Torque limit 20 Nm NOTE = Use only socket head screws, M8 x 35, DIN 6912 (with low head) ! Position of screws, see Arrows ! Attach control 130... 132) Assemble Ist gasket. NOTE : Pay attention to the different gaskets, see Fi- gure 130 and 131 1 Assemble intermediate plate and 2nd gasket. a7 1381.48, Mount flat washers 1 Position of the socket head screw M8 x 60 mm, see Arrow ! eee dete ies oot Penge 2ee ation inthe ‘corresponding ‘Spare. Parte‘way yMIeKa, | Nod saajoye| [Go Sed yUOs au suo} TesISN][] 587 ebpsep yr 40s Gurpuiy You ost Wanipurqaan Weoj Bunaunssny |1p 40) PUTSitt al serentite st visa Soren isan may soy Aeypnng You mae sprmurgan seequ Bau ap at) buts woth al as | . \ 4 te aa 1 \ -— an LE -“ tl | 1 in I ¢ om — [ | eo ltl @oo 4 e 1st1.3.2 Version Il: With 2-stage pressure control valve 1.3.2.1 DISASSEMBLY Relax spring clip and remove cover. Remove components, see Figure on the right. Loosen two socket head screws and fix shift. contrel_housing provisionally, using a Special Toot (5 ). Now, loosen the remaining socket head screws and separate shift-control housing (is spring- loaded) from the valve body by uniform loose- ning of the nuts (5 )- (5) Adjusting screws (M6) 5870 208 089 with nut 1.53Remove stop plate and demount spool as well as spring. Dismantle pressure control valve, see Figure on the left. Dao Remove diphragm and check valves.NOTE : ‘Check all components for damage and renew if necessary ! ‘Check free travel of the moving parts in the housing prior to the installation ! ‘Spools can be exchanged individually 1 ‘Oil components prior to the reassembly ! Employ new O-Rings for all screw plugs and install them. Install check valves and diaphragm (optional). NOTE = Bt! is determined by the diaphragm (pay attention to Notes, Page 1.01 ... 1.03 ) ! Torque limit = Screw plugs MIOxt 20 Nm Screw plugs MISx1,5 35 Nm Diaphragm 20 Nm Close the bores by means of balls (10 pieces, # 4,50 mm). Control. pressure valve = Install components. 1 = Spring (L, = 96,20 mm) 2 = Disk(s) Koptional) 3 = Spool NOTE = is determined by the disk 2 y attention to Notes, Page 1.01 ... 1.03) ! 135 133147 199 1 = Control spool 2 = Spring L, = 124,10 mm) 3 = Spring (Lg = 77,10 mm) 4 = Displacement spool Install components = 1 = Reversing spool 2 = Disk(s) foptional) 3 = Spring (1, = 36,30 mm) NOTE : is determined by the disk 2 attention to Notes, Page 1.01 ... 1.03) ! Ni trol spool (total Jen; 55,30 mm) ‘ 1,30 mm) neo Sens 3 attention to the installation position of spool, sce Figure ! Fe Pre-assemble and attach 2- essure Close the bores by means of balls (4 pieces, # 9,350 mm).Install. comy : Shift-control housing 1 2 = Spool 3 = Spring (L, = 70,30 mmm) 4 Screw 5 = Cylindrical roller (6 x 32 mm) § = Ringe) (optional) 8 = Screw plug 9 = Spring {Lg = 34590 mm) 10 = Spool 11 = Screw plug NOTE = Install two adjusting screws ('S ) and assemble flat gasket. Pull pre-assembled pressure central valve, by means of nuts ( S ) against shoulder and fas- ten it subsequently by means of socket head screws (mount flat washers). Torque limit (M6/8.8) 9,5 Nm (5) Adjusting screw (M6) 3870 204 049 with nut Introduce spool (2) and spring (1), preload and fix them by means of stop plate (3). = Speing {Lg = 51,30 mm) Control spool (total length = 39,50 mm) ste = Spring (Lg = 31.30 mm) Control spool (total length = 39,50 men) (Ly = 31,30 men Gg ) Spool ‘edt pal ‘Spring oem mn cs See thal ctews, (ipteced Speing (1, = 51,30 mm) Pilot spool (total length = 52,50 mm) a3 150 won ifs158 155 136 1.58 157 Torque limit (M5/3.8) 3,5. Nm NOTE: Pay attention to the installation position of the disk (mount between valve body and retaining plate), see Arrow ! Pay attention to the radial installation posi- tion of the solenoid valves, see Figure 156 ! Install cable harness. NOTE Mount new gaskets | Pay attention to the location of the plug nose, see Arrow | Connect the solenoid valves according to the Illustration on the left. Mount new O-Ring, see Arrow, and fix the cover by means of clamping collar. NOTE ‘The Reassembly of the channel plate as well as the attachment of the gearbox control are treated on Page 1.46 ww. 188 | Pay attention to the Perspective Ilustra- tions of the corresponding Spare Parts List !1.3.3 Version I: With WK-Valve and 2estage pressure ‘control valve. 1.33.1, DISASSEMBLY Relax spring clip and remove cover. Pull off the cable shoes and remove cable harness, Loosen socket head screws and remove sole- noid valves.‘Remove components, see Figure on the left. ‘Loosen socket head screws and remove sole- noid valve (2-stage pressure control valve). Loosen two socket head screws and fix shift. central housing provisionally, using a Special Tool (S fran the valve body by ‘ené= SEeméioononing of the tuts (5 ('S) Adjusting screws (M6) 5870 208 049 with nut Remove components of the WK-Yalve as well a of the 2-stage pressure contro! val- ve. 1.68Remove components, see Figure on the right! Remove stop plate (Arrow) and spool as well as spring. Remove diaphragm and check valves. 169 1.65179 mt 1.3.3.2 REASSEMBLY see also Mlustrat ted Table, Page NOTE, Check all components for damage and renew if necessary ! ‘Check free travel of the moving parts in ‘the housing prior to the installation # ‘Spools can be exchanged individually ! Oil components prior to the reassembly [ Ref. Figure 170: 1 un Install components according to the Iustra~ tion on the left. NOTE : Employ new O-Rings for all screw plugs. Figure 171 shows the positions of the O- Rings on the diaphragm 2. (Fasten O-Ring 6 x 1,3 mm/Arrow 2 with grease) ! Ati is determined by the diaphragm 2 (pay attention to Notes, Page 1.01 w. 1.03) ! Torque limit = Screw plug M10x1 20 Nm Screw plug MI8xI,3 35 Nm Diaphragm 20 Nm Close the bores by means. of balls (10 pieces 6 4,50 mm).Control pressure valve = Install components £ = Spring (L, = 96,20 mm) 2 = Disk(s) {eptional) 3 = Spool NOTE : = determined by the disk 2 y attention to Notes, Page 1.01 .. 1.03) ! Reversing valve : components = i i (= 56,30 mem) otal eg «35,30 a, = 51,30 1.67tan i fl a Hg un Hil qe Eel i gil He as12 5 . i 3 3 2 ES i pf le . Le Ht ij . t J fu gia Ge ba whl, pe dasiidl: i sett uit187 1.70 Install Sirah nares (Sed asocee: Me fat gasket (Arrow) shift-control Tai, against shoulder, ting nuts (3) Now, fasten shift-control housing by means of socket head screws (mount flat washers). Torque limit (M6/8.8) 9,5 Nm (S$) Adjusting screws (M6) 5870 204 049 with nut Fasten the two solenoid valves by means of socket head screws. Torque limit (M5/8.8) 5,5. Nm Assemble control spool (K#/KR) and com pression spring (lo = 51,30 mm) and fix ‘them by means of stop plate. NOTE = Position of stop plate, see Arrow ! | Spring @, = 51,30 mm) Control spool (K/KR) = Spring (L, = 51,30 mm) Control spool (K1/K2/K3) Spring (L,, = 37,10 mm) Retaining plate Socket head screws Spring (Ly = 51,30 mm) Pilot spool (total length = 52,50 mm) MeNaue WN oH sInsert solenoid valves and fix them by means ‘of disks, retaining plates and socket head screws. Torque limit (M5/8.8) 5,5 Nm NOTE : Pay attention to the installation position of the disks (mount between valve body and re- taining plate), see Arrow | Pay attention to the installation posi the solenoid valves, see also Figure 191 | Install cable harness. Torque limit (M6/3-8) 9,3 Nm NOTE : Mount new gaskets | Pay attention to the ication of the plug nose see Arrow Connect solenoid valves according to the Il lustration on the right. Mount new O-Ring (Arrow) and fix cover by means of clamping collar. NOTE : ‘The reassembly of the channel plate as well ‘as the attachment of the gearbox control, are ‘treated on Page 1.46 ... 1.08 1 Pay attention to the Perspective Ilustration ‘af the corresponding Spare Parts List | wa 192sind fOr die Ausfhrung nicht. verbindlich fons are not binding for the design rations ne sont pas obl igstotres pour 1*execut ion \dungenvo} 329, | nod sa1)0yHBF|GO sed yUOS wu su wb}s0p win 40) CuTPUIG YOU BIE ut purqaea qua yu Bunsyngsny @1P 4py pays vobunpL gay 210 132 TORQUE CONVERTER : converter connecting clutch (WK) 21 DISASSEMBLY Separate the complete converter from the transmission by means of lifting device. (S) Assembly car compl with tilting device $870 350 000 (S) Basie support 5870 350 014. (8) Support 5870 350 036 (S) Set of eye bolts 5870 204 002 Loosen screwed connection. 2.01Press free wheel inner ring out of the stator and remove released components. Squeeze out snap ring. Press free wheel auter ring out of the sta- tor. Separate turbine wheel from converter im= peller cover. 2.02Loosen hex. head screws, remove backing plate and plate pack. Remove cup spring and demount all criving pins (Arrow) Separate piston from converter impeller cover by means of compressed air. (3) Rubber cap 3870 309 0092.2 REASSEMBLY Squeeze snap ring into the annular groove (Arrow) of the converter impeller cover. NOTE + Install O-Ring (Arrow) and grease it. Thread up profiled bush ( § ) and press the drive dog in until the snap ring engages in the annular groove. NOTE : The snap ring is by means of the profiled bush ( 5 ), thus allowing the reas~ sembly of the drive dog ! (S) Profiled bush 5870 345 073 Install the two rectangular rings, see Arrows! il piston bearing surfaces as well as rect- angular rings and insert piston in the con- verter impeller cover until contact is obtai~ ned. NOTE = Expand the inner rectangular ring (140 x 149 x 2 mm) slightly, to ensure a correct con tact in the piston recess | Install all driving pins (12 pieces) into the bores. 2.08Insert cup spring, with the concave side showing upwards (see draft, fig 17). Determine Dimension I from the straightedge to the outer plate. Dimension I e.g. 44,0 mm (CS) Straightedge 5870 200 022 (S$) Digital depth gauge 5870 200 072 Determine Dimension Il from the straightedge ‘to the contact surface of the backing plate. Dimension I e.g. 43,5 mmDimension I 44,0 mm, Dimension I = 43,5 mm Difference = Clearance mm NOTE Carry out any corrections by means of cor— responding (5 = 9,2 mm, 9,8 mm and 10,5 mm) | Torque limit (M8%25/10.9) 34.Nm (5) Adjusting screw (M%) 5870 204 O11 Fasten turbine wheel hub by means of hex. head screws (mount flat Torque limit (M8x18/8.8) 23. Nm Secure hex. head screws with Loctite (Type- No. 270) ! Heat the ball bearing and mount it against shoulder until contact is obtained.