Order No, $871 162 002 E ZF - POWERSHIFT TRANSMISSION WG-180 WG-200 ZF Passau GmbH Donaustr. 25 - 71 D-94034 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, ications regarding ‘Maintenance, see corresponding Operating Instructions! ZF Passau GmbH Domaustr. 25 - 71 D-94 034 Passau Abt.: ASTDM / Section : ASTDM ‘Nachdruck auch auscugsweise ohne die Gencbmigeng der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Copying even partially not permitted! Reproduction meme par extrait est interdite! Technische Anderungen vorbehalten! With the reserve af technical modifications! ‘Sous reserve de modification techaiques| Ausgabe / Edition : 199402PREFACE ‘This documentation has been developped for the skilled Servicemm, trained by the Zabnradfabrik Passau for the Repair and Maintenance operations on ZF-Units. ‘Treated is a ZE-Serial product according to the design sage 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 aijustment 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 Fricdrichshafen 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 reality, ‘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 exchaded from this contractual responsibility. This applies also in case of a renouncement of Genuine ZF-Spare Parts. Zabnradfabrik Passau GmbH Service Department 0.08GENERAL WORKING INSTRUCTIONS During all operations, pay attention to cleanliness and skilled working. Therefore, Transmissions, removed from the vehicle, aust 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 nmst be carefully removed. Check kubricating holes, grooves and pipes for fice passage, ‘They mst be free of residues, foreign material o¢ protective compounds. ‘The latter refers expecially to new parts. Parts which have been inevitably damaged in a disassembly operation, must be generally replaced by mew 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 etc, which are subject to ‘normal wear in automotive operation, mast 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 arder to assure a proper contact. Before pressing shafts, bearings etc. in position, both parts must be lubricated. During the reassembly, all specified adjusteneat values, testing specifications and torque limits must be respected. AAfier the repair, ZF-Units are filled up with oi ‘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, After the oil filling, the oil level plugs and oil drain plugs must be tightened to th specified torque ‘an 02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. ‘Before starting the work, the Repairers have to make themselves familiar with these Regulativons. ‘The proper Repair of these ZF-Products requires especially trained personnel. ‘The Repairer himself is obliged to pravide for the training. 908Hinweis; lingenbezogine Mafle in kyim; _‘flichenberngene MaBe in vim? Note: linardensity in ky/m; Nota: Density linenive en kg/m; saveal density ist Density superficie en ven? ll aH i [ j 008Vim ( inch) 2,205 Ib { pounds ) 7,233 ibf ft ( pound force foot) 1,356 Nm ( 0,138 kepm ) 1 Taf x fe ( pound force foot ) Lkg/ em 5,560 tb fin ( pound per inch ) 1 bar ( 1,02 kp/em? ) 14,233 pai (pound force per squar inch [hf7in? ) 1 pai ( Ibffin? ) 0,264 Gallon ( Imp. ) 1 Gallon ( Imp. ) 0,220 Gallon (US) 1 Gallon (US } 1 Mile ( Landmeile ) + 32° F ( Fahrenheit ) 273,13 Kelvin 08Metric ISO-Standard Thread DIN 13, Page 13 28 08 41INSCRIPTIONS ON A ZF-MODEL IDENTIFICATION PLATE FOR ZF-HYDROMEDIA- REVERSING-TRANSMISSIONS: 1 = Gearbox type 2 = Gearbox: 2 = ZF-Parts Lict-No, ‘Tatal ratio of the Gearbox Value for the control pressure ZF-Parts List-No. of the Torque Converter Type af the ZF-Torque Converter one eeee Pee ae) aan Grubweg NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine ZF Spore Parts, please indicate: Gearbox type Serial-No. ‘See Model Iderttification Plate! ‘ZF-Parts List-No. Mark and type of vehicle Denomination of the spare part Spare parts-No. Wey of transport When ail of the abave required indications are considered, errors in the delivery of spare part orders can be avoided! Meo ponOptional versions and additional equipment for the transmissions of the WG range 1 Conwarter housing for direct in stallation 2 Torque converter 8 Look-up clutch 4 Cover for separate installation SP 6 7 ber HN 500 convertor transmission Input flange (for separate instal- lation) 8 Centre distance input/output shatts 9 Asie alsconnect unt 10 Parking beaks 11 Speedometer connection 12 Inter-sxle differential 19 Axle drive, fiange*mounted 14 Mulli-disc eluteh for 4,5 and 8-speed version 15 Emorgescy atearing pump 16 PTO unit, engine driven 17 Transmission contro! 16 Steering column switch 8G 4! sce 19 Console switch SG 4/56 6 20 Rotary reversing awiten DW 1 21 Automatic control unit EST 2 22 Inching valve 23 Dual pressure control valve 24 Pressure cut-out 25 Micra-filter 26 Transmission cannection tor ‘eparata fitter instaliation 27 Converter charge anc shift pump(Of -oat Tanmmisios Division ‘Torque converter transmissions for off-road vehicles and machinery (construction plant, special vehicles, lift trucks) List of Lubricants TE-ML 03 Approved lubricants Engine ols wo sors aS APECD) CRY CF) 8/80 wo 100 MIL-L2104 C/-Dy-E wo 1207121 MILL-46152 Cy-Dy-E WO 130131 + SAB OW wo 190181 + SAE 10 W20 wo 200'201 + SAE WO W.40 WG 290 + SAE LS W-40 woes + SAEOW.20 N00 wasn) Foe cemmenateil proces use overeat Fw 25 wit ‘Auromatic Transmission Fivids (ATF) ony at ambient Hsi210 temperamies below ~105C ~ Engine olts SAE 20 W.20 10% sc SAE 1S W-40 -15°C oc SAE 10W, 10 W-30, 10 W-40 20°C sc ATF sore 1c ‘The minimum oil emperaure for stating te vehicle moving can be schiered by: at Jeast 20 minutes’ warm-up in "Newwal” vering preheating At greasing pein, ose 4 mabtcpempose grease withthe following properties: ‘itsiam soap, op point shove 170°C. NLGH Class 2 ‘The grease must he ant-corrosve, water-resitant and walk stable. [Nate ta lubricant suppliors: Please inform ZF imanedistety of ary changes to the composition er trade names of approved product and of ditferences in qulity between Getraany and other couraris. ‘This lst ean be obtained tough any ZF ‘Zaberadfabetk Passau GerbHt Telephone (Ow $1) 434-0 ‘After Sales Service poi Pontfich 26.40 Teles -STHMD apd $290 Passa | Teletax (081) 43 340 0.09 1205 754 105,0192Engine olls API CDICE/CFISE/SG, MIL-L2104 C/-D/-E, MILL 46152 CDE, ster MONERALSR CARH UCT, Baas. bone nahi Can LENO imams. Cemreaoe 394. ace Searuincaliea, wince ‘Re scnmrmesin acter, tuna ‘Seaurerenyocourary. peacreance Seren nv. 2aanasana snaoeo. Tea ‘poco pase sor Nate beet ons suuravers i enc eaTOMADE Engine ails AFI CD/CE/CFISF'SG, MIL-L-2104 C/-D/-E, MIL-L-a6182 CDE, ‘eden SeeATIONAL SC Somme ‘YaLvOuMe permeeaTaAL PC. oxen Saaoel ao exeexemoey oesurenoeELECTRO-HYDRAULIC GEARBOX CONTROL ATTENTION In case of malfunctions of the Transmission because ef a defective gearbox control, we recommend 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-contral curve may not be carried out without agree- ment of ZF. Therefore, the repair of gearbox contro! units should be carried out by ZF- Service stations oaly. The relative shop equipment of our Service stations (gearbox control resp. transmission 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 as 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. 1.01Note regarding the pressure control: Di Precsure-control curve gear case p= Pressure in bar t= Time in secendls p! = Modulation start 5 * Modulation end ~ Modulation surt only in dependence ‘with 2-stage pressure control valve ps = Control pressure AF = Filling time “ENTION: Pp (bar) Pe t (s) ros i rn sicenting othe Traneniadoe enon, mgt wblcte pe and wl be -and diaphragms (optional)! ‘The pressure-control adjusted by means of corresponding shims LozNote: Ia the following Disassembly and Reastembly Instructions are three different gearbox control Variants treated. 1.1 Cast-iron gearbox control 12 Aluminium sawd-casting gearbox control 1.3. Aluminium die-cast gearbax coatral with WK-Valve ‘With the ‘elp af the folewig, Fire, the coordination ofthe sng gearbox contrl variants can be visually idenified because of the different castiig contours! 1.1 Castiron gearbox comico! ; = Central measuring pols for system pressure (Gootrol pressure) ‘Clutch KV ‘Clutch KR ‘Cieteh KI Ctch K2 ‘Clutch KS ‘Gutch Kt saaane & ‘1.2 Aluminium sand-casting gearbox control (ea. 4 magnet) ‘Measuring points for pressure oil: 68 = Central measuring polat for system pressure (control pressure) So Cuesny as (Gatch JEM i case of Senay Version) ‘Cluieh KI Kt ‘Ciuteh Ke (in ease of S-magmet Version) 1.3 Aluminium die-cast gearbox control i" = Central measuring point for system pressure Se4ene & the Perspective Illustrations in the correspandiing Spare Parts List! 1.031.1 CAST-IRON GEARBOX CONTROL V1.1 Version I: Standard Version (without WK and 2-stage pressure control valve) V.lels| DISASSEMBLY Separate itt come Nu gd chatea Loosen socket head screws, install two adjus- ting screws (Arrows) and remove shift-control housing. Now, remove gaskets and intermediate plate. (8) Adjusting serews (M8) 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 sk airy bay by setters ocaming ob he ruts (5). (s) (5) Adjusting screws (M5) 5870 208 036 with nut (5) Adjusting screws (M6) $870 204 089 with nut‘Remove components, see Figure on the right 1 Remove stop plates (Arrows) and demount de- tent blocks. NOTE : The use ef two spools in order to fix the de~ tent block provisionally axially (Figure 10), avoids the tilting of the detent blocks, thus facilitating the disassembly !NOTE = Check all components for damage and renew if necessary } Check free travel of the moving parts in the housing prier to the installation ‘Spools can be exchanged individually ! ‘Oil components prior to the reassembly { Introduce detent blocks (1 and 2) inte: the bores and fix them by means of stop plates G and Install stop plate (5). NOTE: Pay attention to the installation position of the various stop plates, see Figure on the left | is 1.08Valve body ( ‘at (= 8 om a tee 0 Disk {optional) (@)! Pay attention to the General Instructions, Page 1.01 .. 1.03! Install two adjusting screws ($ } and mount flat gasket. Place cover against shoulder, using nuts (5 ). Now, fasten cover by means of screws. Torque limit (M5/8.8) 3.5 Nm (5) Adjusting screws (M5) 5870 204 036 with nut (5) Adjusting screws (M6) 5870 204 049 with nut Install. components : 1 = Yalve body 2 = Spring tL, = 72,9 mm) 3 = Spoal G control surfaces) 4 = Spring (L, = 72,5 mm) 3 = Spool ( contro] surfaces) 6 = Spring (L, = 72,9 mm) 7 = Spool (total length 72,0 mm) % = Detent block G pieces) Install new O-Rings, see Arrows !1.10 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, sce Arrow/Figure 21 ! Mount new O-Ring (160,2 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 Version, different channel jollawing, ling the Standard Version (with control dia~ phragm and diaphragm for the backfeed) ! ‘Wet thread of control diaphragm with Loctite (Type-No. 270), install contro! diaphragm (Po- sition, see Arrow 1), and secure it additionally Install diaphragm for the backfeed (Position, see Arrow 2) accordingly. Insert thread plug (3) with Loctite (Type-No. 270). Ferplay new seciiog hi Sr conmecsing: pg (8) and screw plug (Position, see Arrow 5), them. Attach channel plate and contral Install housing gasket. NOTE = Pay attention to the different gaskets, see Fi- gure 25 and 26 ! (S) Adjusting screws (M8) 5870 204 O11Laz Install intermediate plate and 2nd gasket. Assemble channel plate and fasten it by means of socket head screws. Torque limit (8/8.8) 23 Nm NOTE = Pay attention to a correct position of the hall seat valves Pay attention to the position of the various screws, see corresponding Spare Parts List ! Assemble Ist gasket. NOTE + Pay attention to the different gaskets, see Figure 28 and 23 ! Install intermediate plate and 2nd gasket.Place gearbox contro! assembly against shoul- der and fasten it by means of socket head screws. ‘Torque limit (M8/8-8) 73 Nm NOTE : ee ae he ee serews (lengths) £ scaling for the screw 3 feos Arco) and basal her | oe Now, insall delivery Unes, see Perepective 1 lustrations in the corresponding Spare Parts List 1 1131.2 ALUMINIUM SAND-CASTING GEARBOX CONTROL 1.2.1 Version 1: With 4 Solenoid valves Remove delivery line. (5) Adjusting screws (M8) 5870 200-011 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 1 WAT 3838 Remove stop plates (Arrows) and demount detent blocks (2x). 11845 Pay attention to the installation position | 1 = Spool {total length = 86,00 mm) 2 = Spring (L, = 53,40 mm) nagap2 Is determined by the disk (pay attention to Notes, Page LOT. 1.03) 1 Pressure control valve : Install components, te 2= Spare @, = 132,40 mm) : : =r (15 = 76,70 mm) Control pressure valve + Install companents, i (L, = 78,60 mmd OL, = 65540 mm) (empirical value s = 3.00 mm} (empirical value s = 1400 mm) NOTE : 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)!| é i 1 2 3 = Compression spring — (L,, = 29,90 mm) 4 = Straight pin 3 = Roller 6 = Spool Sa= Disk (s = 2,5 mm/empirical value) i: (L, = 70,90 mm) 3) Screw pligg (mount new O-Ring) 2 NOTE : Insert compression spring (3) and valve (2) in the: peek suet Tx by sienna trait 33 is determined by the dss) 6a aleve baer Be mary 101. 103) 1 Close the bore by means of ball (9 5 mm), see Arrow ! 43 is determined by the ring (@) (pay attention to Notes, Page 1.01 . 1.03) 1 Torque limit (645/88) 5,5 Nm (CS) Adjusting screws (M5) 5870 209 036 with nut (S) Adjusting screws (M6) 3870 209 049 with nut 120(1, = 93,80 mm) (L, = 53,40 mm) (reducing valve) @, = 37,10 mm) (L, = 93,80 mm) Pay attention to the installation position of the components, see Figure 56 Torque limit (M5/8.) 3,3 Nm Insert the solenoid valves and fix them by means of retaining plate and socket head screws. Torque limit (M5/8.8) 5,5 New NOTE + Pay attention to the radial installation posi tien af the solencid valves, see Figure 59 ! Install cable harness. NOTE = Mount new gaskets | Pay attention to the location of the plug nose, see Arrow !al Connect solenoid valves according to the Ml lustration on the right. 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 ! Pay attention to the Perspective Illustration of the corresponding Spare Parts List | Pre-assemble channel plate 62... 64) = responding Parts List The fc Reassembly Instruction is trea- ting the Version with for the back- feed (without contra! agin Wet thread of diaphragm with Loctite (Type No. 270), install diaphragm (Position, see Ar- row 1) and secure it additionally by means of center punch. Now, clean diaphragm from Loctite residues by means of compressed air. Install thread plug (Position, sce Arrow 2) ac cordingly.Install connecting pipe (1) and screw plug (Arrow). Attach channel plate and control (Figure G5... G8): NOTE = Pay attention to the installation position of the components, see corresponding Spare (5) Adjusting screws (M8) 9870 208 O11 ‘Assemble channel plate and fasten it by means of socket head screws. Torque limit 201Nm 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 2nd gasket. NOTE + Pay attention to the various gaskets, see cor- responding Spare Parts List ! Place control unit against shoulder until contact is obtained and fasten it by meens of hex. head screws (mount flat washers). Torque limit 20 Nm Install delivery lines eccording to the Mlustra-~ tion in the Spare Parts List NOTE = Mount new sealing rings 1 1.25wo}IM20Ra, | Mod SasyOHRG} Ge sed ios BU suOyAeVIShAT) 501 uBrsap ein 40) BuIDUTG tou BAN cuOIZeugSmT TT 4D 1 TPuIadan qUDTU GuRJUNZSMY BTP ans pus vaBUNDLIaEy aya ~ 126+vonqrayy ana saijeteijga Sed qos ou seq eure say ers=9- ain 294 fanpage, you axe sore SPHPETION KPI BunDEEMY =P 40) PARE vabUMPHERY OIC) A /\ t/ \ Jt % Sait | See \/ \ fara iV a a \ Apt ey ates « tom oe—--5\aie a. 1.2.2 Version Il: With 3 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 : Remove 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-comtral housing (is spring-loaded) from the valve body by uni- form loosening of the nuts (S$ ). (s) eis screws (M3) 5870 208 036 with nut CS) Adjusting screws (Mé) 5870 208 049 with nut Remove components. Remove stop plates (see Arrows) and de- mount the remaining components:1.2.2.2 REASSEMBLY see_also_Mlustrated_T: Page 1.35 T NOTE = Check all components Jor 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 #,50 mm)! Introduce detent block | and fix it by means of the stop plate 4. Install subsequently spool 2 and spring 3 (Lo = 31,3 mm), and fix them by means of the stop te Se Install spool 6, spring 7 (Lo = 53,4 mm) and detent block 8) and fix them by means of the stop plate Irasit dere ce Ta NOTE : Pay attention to the installation position of the different stop plates, see Figure on the 1 = Spring (L, = 33,40 mm) 2 = Spool Reset 1 Install components. 1 = Spool 2 = Diskls) (optional) 3 = Spring (Ly, = 58,00 min) 4% = Spring (8 = 65,90 mm) NOTE = is determined by the disk 4 (pay attention to Notes, Page 1.01 -. 1.03) | 4st | is determined by the disk 2 jay attention to Notes, Page 1.01 ... 1.03) ! Control pressure valve + | (L, = 65,40 mm) as = 78,60 mm) (optional) (optional) auew Ne is determined by the disks 3 and 4 iy attention to Notes, Page 1.01 ... 1.03) f 89 Sian ciehagi by nein At tons, (ype No. 275) 1 Now, clean dlaphragm from Loctite residues by means of compressed ait 12 (Modulation time-WK) Is ‘Geberidned by the diaphragen 2 {pay attention to Notes, Page 1.01 ... 1.03) 1 Install two adjusting screws ( $ ) and mount gasket (Arrow). {) Adjusting screws (M3) 5870 204 036 with nut (|S) Adjusting screws (Mé) 5870 204 O49 with nuto roe Pull shift-control housing by means of threa- ded bushings (5) against shoulder. Now, fasten housing by means od socket head screws. Torque limit (M3/8.8) 3,5.Nm (5) Adjusting screws (M3) 5870 209 036 with mut (5) Adjusting screws (M6) 5870 200 049 with nut Install components : 1 = Shift-controt housing 2 = ORing 3 = Solenoid valve 4 = Socket head screws (with washer) 5 = Spring (L, = 53,80 mm 6 = Disk(s) (optional) 7 = Spool & = Screw plug (with O-Ring) NOTE + 2 is determined by the disk 6 yy attention to Notes, Page 1.01... 1.03)! Install components = Shift-control ne Spring = 31,30 mm) ‘Spool Spring (Lo = 37,10 mm) 1 2 2 4 3s 6 = Spool fixing (retaining plate and Tv 8 9 1 = Spring (L, = 53,40 mm) = Spool = Retaining plate and socket head screw = Solenoid valves (33) Pay attention to the installation position of the solenoid valves, see Figure 95 ! Install cable harness. NOTE = ‘Mount new: 151 ‘Pay attention to the Spent atthe phage see Arraw ! 133Connect solenoid valves according to the I~ lustration on the left. 95 = Mount naw O-Rleg (sisi a $57) aod tice ver by means of clamping collar. Install screw plugs as well as control pres- sure sender (according, to the Version). NOTE + ‘The Reassembly of the channel plate as welll as the attachment of the gearbox control is treated on Page 1.23 .. 125! Pay attention to the Perspective Illustration of the corresponding Spare Parts List ! (CS) Adjusting screws (M8) 5870 204 O11wojanrar, | med saujoqeO} [qu sed U0 au suoyeAyER| TT 537 wbTIOp sya 40) GuIDuNG You sae SuBfyeAasnt tt ver rporasee quote Buns W 1D 40d pUIs WaduMDY jaa 9101.3. ALUMINIUM DIE-CAST GEARBOX CONTROL 13d ¥ With WkK-Valve 1.3.11 DISASSEMBLY (3) Adjusting screws 3870 204 O11 Relax spring clip and remove cover. Loosen socket head screws and demount sole~ noid valves.140 Remove components, see Figure on the left! Separate WK-Shift-contral housing from the valve body and dismantle it, see Figure on the left ! Loosen two socket head screws and fix the shift-control housing provisionally, using a Special Tool (5 ). Now, loosen the socket head screws and separate cover (is spring-loaded) from the valve body by uniform loosening of the nuts (5). (5) Adjusting screws (Mé) 5870 206 049 with nutRemove components, see Figure on the right ! Remave stop plate and demount spring as well as spool. NOTE = Installation position of the stop plate, see Ar- row Remove diaphragm and check valves. 3 4= 1.3.1.2 REASSEMBL Y see also Illustrated Tables, Page 1.49 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 | ill Components prior to the reassembly | bly! Atl is determined by the diaphragm (pay attention to Notes, Page 1.01 ... 1.03)! Torque limit : Screw plug Mrdxt 20 Nm Screw plug MISxI,5 35 Nm Diaphragm 20 Nm Close the bores by means off balls (10 pie ces, @ 4,50 mm).mt Vaz Control pressure valve + ‘Install components, 1 = Spring (L, = 96,20 mm) 2 = Disk(s) foptional) 3 = Spool P3 NOTE + determined by the disk ps is {pay attention to Notes, Page 1.01 ... 1.03) 1 Pressure control valve : 24,10 mm) t 77,10 mm) 2 3 4 Install disk 4, with the countersinking facing. 6 ‘the compression spring ! 1 is determined by the disk 5 mB (pay attention to Notes, Pages 1-01. 1.03) t ‘Reversing valve : ‘Install components. 1 = Reversing spool 2 = Speing (L,, = 56,30 mm) 1 a 114 ‘Control KY Install components. 1 = Spool {total length = 55,50 mm) 2 = Spring tL, = 51,30 mm)"7 Install two adjusting screws ( 5) and assem= ble flat gasket (Arrow). Now, pull cover against shoulder, using nuts (3 ) and fix it provisionally by means of Scat heed acres pieces, see Figure " (CS) Adjusting screws (M6) 5870 20% 049 with nut 1 2 = O-Ring 3 = Screw plug 4 = Spool 3 = Disks {optional} 6 w Spin (1, = 53,49 mm) 7 = Detent block {spring guide) 3 = O-Ring 9 = Connecting piece NOTE: Install detent block 7 with the countersin- king facing the spring ! 2 is determined by the disk 5 {poy attention to Notes, Page 1.01. 1.03 | Fasten shift-control housing and cover by means of socket head screws (mount flat washers). Torque limit (M6/8.8) 9.5 Nm (3) Adjusting screws (Mé) 5870 204 049 with nut Mount new O-Rings (Arrows) and fasten so- Torque limit (M3/8.8) 3,3.Nmus Introduce control spool (K#/KR) and compres- don poston (ia 2 Sisto aad SE meee hy means of stop plate. NOTE : Position of the stop plate, see Arrow I Pee 1 = Spring tL, = 91,30 mm) 2 = Controt KARR 3 = Spring vt 1 20 mm) 4 = Control spool KI/K2/K3 a = Spring (Lo = 37,10 mm) 1Gonnect solenoid valves according to the Figure on the left. Mount new O-Ring (Arrow) and fix cover by means of clamping collar. 726... 129) Mount connecting pipe (1) and screw alug (2. Install two adjusting screws and assemble housing gasket. NOTE = Pay attention to the different gaskets, see Figure 127 and 128 | (8) Adjusting screws (M3) 5870 209 011oa 1th Install intermediate plate and 2nd gasket. Assemble channel plate and fasten by means Bt coset head scrive Gone at wakes Torque limit 20.Nm NOTE = Use only socket head screws, M8 x 35, DIN 6812 (with low head) | Position of screws, see Arrows ! Attach contra 130 13; Assemble Ist gasket. NOTE + Pay attention to the different gaskets, see Fi- gure 130 and 1311 Assemble intermediate plate and 2nd gasket.st (ul Mount flat washers 1 Position of the socket head screw MS x 60 mm, see Arrow ! Install delivery lines, see Perspective Illus- fratlon Inthe corresponding Spare ParcsAd ‘vopyona | snd sas]o86| [go Sed UOS au ELOFIENSM tT S37 obrsep ua aug Gutpurg You axe seo} esnTT ADTTpUIGses TwOTU GoRsUNySAY @IP 2m) PUTS wobunOL TARY B101.49 oy ynoexa, | anod seuyeyeOy TGS Sed quos au suOTTEARENITT Say uOysip oa) 44 Cuspurg 30u Bue SuOPaRARSNTTT ay TpurqseA 2u2]u GunsuNsRrY OTB: 404 DUTT UABUNOTTOGY #10151 1.3.2 Version Tl: With 2-stage pressure control valve ‘1.3.2.1 DISASSEMBLY Relax spring, clip and remove cover. Remove components, see Figure on the right. toad tree the valve bndy by ulcers loves ning of the nuts (5 ). (5) Adjusting screws (M6) 3870 208 099 with nut1.53 Remove stop plate and cemount spool as well as spring. Dismantle pressure contro] valve, see Figure on the left. 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 1 Spools can be exchanged individually t ‘Gil components prior to the reassembly ! Employ new O-Rings for all screw plugs and install them. Install check valves and diaphragm (optional). NOTE = Mount new O-1 Fasten O-Ring 6x1,5 mm (Arrow) with grease ‘on the end face of the diaphragm - makes the reassembly easier ! OUI is determined by the diaphr pay etbention to. Aesiay, Page 101 soe 1.03 1 Torque limit = Screw plugs M10x1 20. Nm Screw plugs MISx1,5 35. Nm Diaphragm 20. Nm Close the bores by means of balls (10 pieces, 64,50 mm). Control pressure valve = Install components. o, = 96,20 mm) {optional} NOTE: ps is determined by the disk (pay attention to Notes, ay 1.01 ... 1.03) #17 155 1 = Contre! spool 2 = Spring QL, = 124,10 mm) 3 = Spring (13 = 77,10 mm) 4 = Displacement spool Install components ¢ 1 = Reversing spool 2 = Disks) (optional) 3 = Spring iL, = 36:30 mm) NOTE = is determined by the disk 2 attention to Notes, Page 1.01 ... 1.03) ! Install components + 1 = Control spool (total length = 55,56 mm) 2 = Spring iL, = 51,30 mm) NOTE + Pay attention to the installation position of ‘the spool, see Figure ! Close the bores by means of balls (¢ pieces, 9,30 mm).149 Install components = Shift-control housing te 2 = Spool 2 = Spring {L,, = 70,90 mm) & = Screw plug 35 = Cylindrical roller (6 x 32 mm) & = Ringts) (optional) 7 = Spool 8 = Screw plug er fh, = 34,90 mm) 1 11 = Screw plug NOTE : is determined by the ring 6 yy attention to Notes, Page 1-01 -«. 1.03) # Pay attention to the installation position of ‘the spool (7), bore is facing the screw plug. ! Employ new O-Rings for ecrew plugs | Install two adjusting screws ( 5 ) and assemble flat gasket. Pull pre-assembled pressure control valve by means of nuts ('S ) against shoulder and’ ta5- ‘ten it subsequently by means of socket head screws (mount flat washers). Torque limit (M6/8.8) 9,5 Nm (3) Adjusting screw (M6) 5870 208 089 with nut Introduce spoo! (2) and spring (1), preload and fix them by means of stop plate (3) 1 = Spring (L, = 91,30 mm) 2 = Control spool (total length = 39,50 mm) 3 = Stop plate (L, = 31.30 mm) 1 2 = Control spool (total length = 39,50 mm) 3 = Spring (L, = 31.30 mm) 4 = Control spool 5 = Spool (reducing valve) 6 = Spring (L, = 37,10 mm) 7=R te 3% = Socket head screws (2 pieces) 9 = Spring (L, = 51,30 mm) 10 = Pilot spool (total length = 52,50 mm)Torque limit (M5/8.8) 5,5 New NOTE : Pay attention to the installation position of the disk (mount between valve body and Connect the solenoid valves according to the Illustration on the left, 156 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 contral are treated on Page 1.06 .. 188 Pay attention to the Perspective Mustra- tions of the corresponding Spare Parts List !—— 137 way Roar, | anod sauyoqe6] 190 Sed URS ay SUOTLeA wOYS9p O49 40) BuIpHIG yO ax” S40) PH IPUgIEN WeETU BunayORsOY BIp 4B) PUTS UeBenD|1.3.3 Version II]: With WK-Valve and variable 2-stage pressure ‘control valve. 1.3.3.1 DISASSEMBLY Relax spring clip and remove covers Pull off the cable shces and remove cable harness. Loosen socket head screws and remove sole noid valves.165 1.63 ez 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- Sacro. hectare: vidal ne 8) SHScR Now, ‘loasen the remaining socket, head . hi -contral housing (is Bia looming ofthe aut Cok (5) Adjusting screws (M6) 5270 204 049 with nut components of the WK-Valve as wal oo oe ae olage pressure contro! val- ve.Remove components see Figure on the right! Remave stop plate (Arrow) and spool as well as spring: Remove diaphragm and check valves. 169163 1.3.3.2 REASSEMBLY es Slay Teena Tete Page 172 NOTE Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation 1 can be exchanged individually ! Oil components prior to the reassembly ! Ret, Figure 1701 | = Check valve (2x) 2 = Diaphragm Screw plugs Install components according to the Mlustra~ tion on the left. NOTE = Employ new O-Rings for all screw plugs. Figure 171 sin the pealtions ct, MeO Rings on the diaphragm rope O-Ring 6 x 1,5 oenjArrow 2 with BU! is determined by the diaphragm (pay attention to Notes, Page 1.01... aa 1 Torque limit = Screw plug MIOx! 20 Nm Screw plug M13K1,2 32Nm Diaphragm 20 Nm Close the bores by means of balls (10 pieces 4,50 mm).Control pressure valve Install components + = Spring (L, = 96:20 mm) Disks) {optional} Spool NOTE = wn = is determined by the disk 2 y attention to Notes, Page 1.01 4. 1-03) ! Pressure control valve = Install components + 1 = Control spool 2 = Spring {L, = 124,10 mm) 3 = Spring W2 = 77,10 mm) 4% = Displacement spool ‘Reversing valve components = : ff Spring (L, = 58,30 mm) 1 = Spool (total length = 33,50 mm) 2 = Spring (= 3,30 mm)76. is. ad determined by the diaphragm seta fo Boe Pane eet ae LA 28b i j HH wounie ramen F 4 is determined by the disk 2 attention to Notes, Page 1.01 ... 1.03) | Intall detent block with the ‘the spring ! be Install screw plug (Arrow). NOTE : Assemble new O-Ring { Torque limit (M10x1) 3 3 Pressure control valve mm) = 70,90 he eadee ¢= 500 and i | nog ae i weenon ramene nw 3 i if aHInstall two adjusting screws (5 ) and assem- ble flat gasket (Arrow). Pull shift-control housing against shoulder, using nuts (5). ‘af socket head screws (mount flat washers). Torque limit (M6/8.8) 9,3 Nem (S) Adjusting screws (M6) 5870 204 045 with nut Fasten the two solenoid valves by means of ‘socket head screws, Torque limit (M5/8.8) 5,5 Nm Assemble control spool (K4/KR) and com- pression spring (Lo = 51,30 mm) and fix ‘them by means of stop plate. NOTE = Position of stop plate, see Arrow Install components = Spring (L, = 31,30 mm) Control (<4/KRD Speing i (1, = 51,30 mm) Control spool (KI/K2/K3) Spring (1, = 37510 mm) Retaining plate Socket head ‘screws Spring (1, = 31,30 mm) Pilot spool (total Jength = 52,50 mm)170 Insert solenoid valves and fix them by means of disks, retaining plates and socket head screws, Torque limit (M5/8.8) 3,3 Nm NOTE : Pay attention to the installation position of the disks (mount between valve body and te- taining plate), see Arrow ! Pay attention to the installation position of the solenoid valves, see also Figure 191 1 Install cable harness. Torque limit (M6/8.8) 9,3 Nm NOTE = Mount new gaskets | Pay attention to the location of the plug nose see Arrow 1 Connect solencid valves according to the I- 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 eated on Page 1.06... 1.08 1 Pay attention to the Perspective Mlustration of the corresponding Spare Parts List |wor ynoaxa, | anod sauyureBy qe sed quand au suo) yeaysny |} Se \ \ \ etd ~~ CEEbes ed < = S ‘ yacenalus } (Wk) 21 DISASSEMBLY Separate the complete converter from the by means of lifting dev: (S) Assembly car compl. with tilting device 5870 350 000 (S)Basic support 5870 350.014 (8) Support 5870 350 036 (S) Set of eye bolts ‘$870 204 002 ‘Loosen screwed connection. Install hex. head screw, tap impeller wheel Boer en scenen te bre meee eee cover, see Figure 1 ‘Loosen hex. head screws and remove impelfer wheel flange.Press free wheel inner ring out of the stator and remove released components. Squeeze out snap ring. Press free wheel outer ring out of the sta~ ‘tors Separate turbine wheel from converter im- peller cover.Remove cup spring and demount all driving pie Carrowk Separate piston from converter impeller cover by means of compressed air. (3) Rubber cap 5870 509 009 Press profiled bush out of the converter im= peller cover. NOTE ¢ The profiled bush is axially fixed by means of 5 fate ting ble stl te Sinan athe pressing out. #203 22 REASSEMBLY Squeeze snap ring into the annular groove (Arrow) of the converter impeller cover. NOTE Grease and rh ly prior to reassemble sretprettea buen ig trigure 8) 1 5870 345 073 Install the two rectangular rings see Arrows! Oil piston bearing surfaces as well as rect- angular rings and insert piston in the con verter impeller cover until contact is obtai- ii NOTE = ‘the inner rectangular ring (140 x 189 mm) slightly, to ensure a correct con- tact in the piston recess ! Install all driving pins (12 pieces) into the bores.Dimension F e.g. 44,0 mm (S) Straightedge 5870 200 G22 (5) Digital depth gauge 3870 200 O72 Determine Dimension I from the straightedge Yo the contact surface of the backing plate. Dimension 1 e.g. 93,5 mma Example "A": Dimension I 44,0 mm Dimension It = 43,5 mm, Difference = Clearance mm NOTE : Carry wut any corrections by means of cor responding pistons (s = 9,2 mm, 9,8 mm and 10,3 mm) | ‘Assemble backing plate with the chamfering (Arrow) showing upwards and fasten it by means of hex. head screws. Torque limit (M8x23/10.9) 34 Nm (3) Adjusting screw (MB) 5870 204 O11 Fasten turbine wheel hub by means of hex. head screws (mount flat washers). 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 wntil contact is obtained.Seqrae In ctangnlar eg (Arrow 1) and it. Bee Insert O-Ring (Arrow 2) in the recess of the ‘turbine wheel hub and grease it. Thread up pre-assembled turbine wheel until the inner plates have been received. Heat stator and insert free wheel outer ring until contact is obtained. Fix free wheel outer ring by means of snap ring.2.07 : oe & ul The statoc end play is determined by means of shim 10, see Example "B" Kneert bosting, rollers, serings are! smh caps (8, 7, and 6) according to Place ball bearing (2) on the long hub sic (24 mm) against shoulder, install thrust was- her (3) 5 = 1,3. mm and press free wheel in— ner ring against shoulder, Press caps by means of guide plate (3) into the free wheel ring until the cy lindrical roller pairs (5) can be installed. (S) Guide plate 5870 365 020Mount thrust washer (3) s = 1,5 mm and press bearing against shoulder. Install shim (1) 5 = 1,0 mm and shalt washer {6OxB5x4,7 5). ite side : Install shim (1) s = 1,0 mm, shim (10) {optio~ nal eges = 0,5 mm) and shaft washer (6Ox85x 4,75). NOTE : The end play of the stator is determined by means of shim (10) (e.g. s = 0,5 mm/empirical value) 1 However, a later check (Figure 39 .. Example "B") is absolutely essential | Mount housing washer (62x85x9,75 mm) and axial needle bearing (60x85x3 mm).Install anal eller Bearing emt howsirg, was her (62x85x4,75 mm). Mount new flat gasket and fasten tlonge by means of hex. head screws (mount flat was- ‘hees) on the impeller wheel. Torque limit (M&x18/8.8) 23 Nm NOTE : Pay attention to the radial installation posi hex. head screws with Loctite (Type Mount flat gasket (Arrow). Determine Dimension { from the fange~ (gasket) mounted surface to the plane sur- face/impelier wheel tlange. Dimension 1 e.g. 88,03 mm (s) s 5870 200 022 (5) Gauge blocks 3870 200 066 (CS) Digital depth gauge 5870 200 072= — 2.10 38 Measure Dimension Il from the fi MS surface (converter inpeller ove) 0 the housing washer. Dimension e.g. 27,95 mm Example "B" + Dimension I Dimension 1 Difference = End NOTE : In case of deviations from the permitted end play (max. 0,2 mm) correct by means of cor- shim f The shim is illustrated on Figure 34 ! Screw two adjusting screws into the converter impeller cover and mount flat gasket. Place impeller wheel against shoulder and fas- ten it by means of hex. head screws. Torque limit (MBx32/8.8) 23 Nm NOTE + Install flat washers ! Pay attention to the radial position, sce mar- kings | (S) Adjusting screw (M8) 5870 206 O11 Squeeze the rectangular ring into the annular groove (Arrow) and engage it. NOTE : Installl converter, see Page 3.77 12 3 3.1.1 CONVERTER CHARGE PUMP and CONTROL PRESSURE PUMP Loosen hollow screw and remove delivery line. Loosen screwed connection (Fi 2) and se~ parate engine connecting case from gear case by means of pry bars (Figure 3). Loosen hollow screw and remove delivery line.Loosen hex. head screws. Tap loose and remove bearing cap. tpemadser matte Ye by means of hex. head screws. Pull converter charge pump and prem ra (compe oof the ag (5) Backe-off device 3870 000 062 Loosen hex. head screws and separate pump from ail supply flange.3.02 Remove rectangular ring (1) and circlip (2). (S) Set of external 5870 900 O16 snap ring pliers Press shaft out of the pump case. Check converter a and contral pressure pump (Figure 11 ... Ta) = Remove the two straight pins by means of striker (Figure 11), loosen hex. head screws and remave cover (Figure 12) | (8) Striter 5870 650 901 NOTE = If traces of wear should be encountered in the pump case or an the housing cover, the com- plete pump has to be renewed !3.03 RB Install rotor set, fix cover provisionally by means of hex. head screws and insert the straight pins (with the tapped hole showing upwards) until contact is obtained. Fix the straight pins axially by means of caulkings (2x) and tighten hex. head screws finally. Remove converter relief valve {ball and spring). Squeeze out circlip. (5) Set of external 3870 900 O16 snap ring pliers Press drive shaft in direction of Arrow until the spur gear is released.3.04 Remove disk and spur gear. NOTE > According to the Version, with or without disk see corresponding Spare Parts List ! Remove ball bearing and drive shaft. Pull roller bearing out of the bore. (S) Internal puller 5870 300 019 (S) Back-up tool 5870 300 003 Remove temperature connection.3.05 Loosen screw remove converter control valve So of disk, compres sion spring, spool and valve sleeves Remove drive side inductive transmitter. 3.1.2 COAXIAL POWER TAKE-OFF G Loosen clamping screw and remove lever (Arrow). Remove Woodruff key and shift lever.Remove locking device. Loosen socket head screws and remove hou- sing. Loosen hex. head screws and lift complete power take-off housing out of the bore. (S) Set of eye bolts 3870 204 0923.07 For this step, an assistant is absolutely necessary ! (S) Circlip pliers ‘5870 900 026 NOTE : Pay attention to the released components !3.08 313 LATERAL POWER TAKE-OFF i : : i i i i |3.09 Bald |OVE EMERGENCY STEERING Loosen hex. nuts and separate emergency steering pump from gear case.3.10 3.1.5 REMOVE MULTI-DISK CLUTCHES NOTE : In case of Versions with -ar_fixing KL the two set screws (Arran we fo be remo- ved priot to the disassembly of the axle, see Figure on the right ! Lift clutch out of the gear case and deposit it. NOTE Use lunting device Remove clutch KR/K2 accordingly. In the case of clutch K4/K3, push the lower spacing washer to the rear. Only then, the clutch can be removed. (3) Lifting device 3870 330 O41 3.1.6 REMOVE COUNTERSHAFT ASSEMBLY Remove closing cover.Loosen socket head screw. Pull axle by means of Special device out of ‘the housing bore, resp. spur gear bearing. (S) Puller 5870 000 083 Remove spur gear and disk.3012 3.17 DISMANTLE MULTI-DISK CLUTCH Remove spur gear KI and demount compo- nents. ‘Squeeze out snap ring. Remove plate pack. Preload compression spring, squeeze out cir clip and remove components. 4S) Assembly jig 3870 349 O783.13 a Remove piston by means of clamping pliers. (5) Clamping pliers 3870 990 007 Pull needle bush out af the bore, using in- ternal puller. NOTE = The disassembly of the clutch KV, KR/K2 and Ki/K3 has to be carried out accordingly. (5) Internal puller 5870 300 O14 (S$) Back-up tool 5870 300 0033.14 3.1.8 FINAL DRIVE - VERSION WITH BRUM BRAKE Remove lock plate and loosen hex. head screws., Pry output flange aff the shaft. (3) Pry bar 5870 345 065 Tilt gear case 180%. Loosen hex. head screws. Separate brake drum from output flange. (5) Crow bar 5870 345 O713.5 3 Remove lock plate and loosen hex. head screws. Pull output flange from the shaft. (5) Twe-teg puller 5870 970 00% Unhock return springs and remove brake shoes. (5) Brake spring pliers 3870 900 006 Pry shaft seal out of the housing bore. (S) Crow bar 5870 345 071or Squeeze out circlip and remove shim. (8) Ciretip pliers 3870 900 O21 Loosen the two closing covers by central tap- ping and remove them. Loosen the two hex. head screws and remove them along with flat washers. Remove upper oil retainer.217 Drive output shaft by means of striker out ‘of the output gear and remove it. ATTENTION + Jn cope of the, Version with,» mechanical the speedometer-drive shaft (Cope) To Be ered. prior to the disassembly of the output shat (5) Puller $870 023 O17 (3S) Puller 5870 023 026 (3) Striker 5870 650 O01 Remove output gear and plate. Squeeze out circlip and remove beake cam. (3) Set of external 3870 900 O15 ‘snap ring pliers Drive the pin out of the housing bore and remove it.Tit case 180°, Pry thaft seal out of the housing, bore. Sagi eA ge (5) Circlip pliers 5870 900 021319 3.2 REASSEMBLY 3.2.1 Final drive - Version with Drum brake Install O-Ring (Arrow), insert pin until con- tact is obtained and fasten by means of hou- sing washer, flat washer and hex. head screw. NOTE : Spar bees he acra wish Tneitin (Types: 270) | Mlustration on the right shows the components ‘of the brake cam. sa 23.21 NOTE : For the following steps pay attention to the Draft (Figure 93) 1 ‘Squeeze in circlip 1. Tilt gear case 180°, (5) Clamping pliers 3870 900 021Heat bearing inner race 5 and assemble it un- til contact is obtained. Position spur gear 6, see Draft ! Position oil retainer 7, see Draft 1323 Fasten both plates by means of hex. head screws (install flat washers). Torque limit (M8/3.8) 23 Nm j ‘Secure hex, head screws with Loctite (Type No. 270). ‘Squeeze in cirelip 8. (5) Clamping pliers 3870 990 O21 NOTE Thread up output shaft 9 until contact is obtained.‘Check _end ‘of the shaft_beari 20,3 = 05 mm 10... Example "A\ Measure Dimension I from the end facefout~ put shaft to the contact face (ball bearing). Dimension I cage 79,60 mm (S) Digital depth gauge 5870 200 O72 Determine Dimension II fram the end face/out- Put shaft to the upper plane surface of the Dimension I e.g. 79,10 mm Example "A": Dimension 1 79,69 mm Dimension I = 7210 mm In case of deviations from the required end play, correct by means of a corresponding shim (2), see Figure 93 ! Press ball bearing against shoulder.325 Heat housing bore and thread up output shaft until contact is obtained. Fix ball bearing free of play by means of shim and circlip. (5) Clamping pliers 5870 900 921 Install shatt seal with the sealing lip facing the oil chamber. NOTE = The exact installation position is obtained by application of the prescribed driver ! If the outer diameter of the shaft seal is rubberized, wet the sealing surface with spi- rit! If not, use sealing compound (Curil 1) ! Grease sealing lip ! (8) Driver 5870 O%8 067 The Figure on the left shows a Version with ‘two shaft seals (Version with fording ability) See ET iti the oll chamber. Sealing ‘seal 5 facing the oil chamber. Sealing outwards. Fill space between upper and lower sealing lip with grease |(3S) Driver Install the two closing covers. NOTE + et sealing surfaces with Loctite (Type-No. 270) 1 (S) Driver 5870 057 G15 (S$) Handle 5870 260 002 Install brake shoes and engage return springs. 13 Heat output flange and assemble it until con- tact is obtained.NOTE Wet the contact surface of disk and screw heads with sealing compound ! Torque limit (M10/3.8) 46 Nm Fix hex. head screws by means of lock plate 5) Driver 3870 037 009 5) Handle 3870 260 002 Assemble brake drum and fasten it by means of hex. head screws (mount flat was- Torque limit (M10/10.9) 68 Nm (S) Adjusting screws (MIO) 5870 20% 007Y Saas | (8). Driver 3870 088 067 3.28 ire 119 sh & Verein, wish 2 shalt als Weralan wh Seog Sb) Installation sees oo aa eae cil chamber Sealing lip of outer shaft seal is showing out- The installation depth is obtained by applica- tion of the prescribed driver | NOTE = Fill space of upper and lower sealing lip with grease ! (5) Driver 5870 098 067 Insert hex. head screws in the bores, heat the ‘output flange and assemble it until contact is obtained. Fasten output flange by means of disk and screws. hex. head NOTE = Wet contact areas of disk and screw heads with sealing compound ! Torque limit (M10/8-8) 96 Nm Fix hex. head screws by means af lock plate. na ) Driver 5870 057 009 ) Handle 5870 260 0023.29 3.2.2 ‘Speedometer The Illustration on the left shows the com- Press drive flat against the end face/ speedometersdrive shaft Introduce spcedemeter-drive shaft and fix it by moans of straight pin.aT 2.30 Assemble flat gasket and fasten pre-assem- bled speedometer by means of hex. head screws. Torque limit (M3/8.8) 23.Nm In case of the Version without close the bore by means of cover Uierow. NOTE = Wet qoaileg surfaces with Loctite (Type-No. 270)331 32.3 CLUTCH KA/K3 3.2.3.1 Pre-assemble plate carrier K4/K3 NOTE + Lads ie igure 132 ... 138) have Sitin boa wis ot the plate a Press needle bush carefully against shoulder, using deift (5 ). NOTE : ‘The needle bush is marked on one end face. At the pressing in, the marking must be show- ing upwards (to the drift) F (CS) Drift 5870 506 O55 ‘Check operation of the bleeder valves. NOTE : Ball may not stick, If necessary, clean it by means of compressed air or renew it! Insert the profiled sealing rings (Arrows) in the recesses of the piston with the sealing lip. facing the pressure chamber. NOTE : Oil profiled sealing rings and insert piston un- til contact is obtained. NOTE : Use installer (5S ) | (5) Installer 5870 651 023 132 133 143.33 135 . Assemble lower spring guide (I), ci <<. ba, sion spring (2) and upper spring, guide (3 ow 4 136 Mount guide ring (9) and circlip (5) (Figure 137), preload compression spring and fix the companents by means of circlip (Figure 138). Assembly jig 5870 343 0283.38 PLATE INSTALLATION I. Determine Plate installation-No. (Page 3.35) IL Table for plate installation (Page 3.36 ... 3.360) IL Example with Draft (Page 3.364) Ref; Determine Plate installations-No. with the aid of the corresponding Spare Parts Lis. ‘The following List shows the abstract fram a Spare Parts List A = Transmission Parts List B= Group 151, Clutch KV/K1 ‘C = Assembly Note - Plate installation D = Plate installation-No. ‘The Transmission Parts List (see Model Identification Plate) must be identical with thecorresponding Parts List of the Spare Parts List! ‘The Plate installations-No. can be found om the left Table margin of the following Pages G.36a ... 3.360)! 335 IL. Table for Plate installation Clutch KV and KR cimmt fs [Outer plate ny 6 D501 308 330 a or a 22, = teu som Soom 5 3 7 aa ny 2 RS [Compensating pie T in 2 RTD ei | 25 ors. 4644 308 330 i Re a ié [Plats clearance 2A [Outer ple i 2 a Taso ; = = ny ia CET EE & al [ewer place 1 23 Ex ‘Heid 308 330%) =| 2% [Compensating pine T 20 20 aad 0879 i #1 5 2s wis 44 308330 3 [No of fetion sufaome z = [Piste clearance 3638 [Outer pase ¥ 2 16 CoTECEr $ | 5. [timerplawe 7 aS is. ‘sea 308330 i 3 Omer pine ot | g 2 [Cempensaing pie T 1S 1S Tea eT 3 2 |coumpamy «2s | «20 sua 308 0148) § [BD fhe cthiaion nation Tf Plate cesrance 23a © [ower pla z zp 16 301 308330 | gy |tmerpue 7 25 iS $644 308330 i a] [inner plate 2 | 8 E [Cempensing paw T ry is 5B cone pst) 20 «20 4644 308 014°") 2 | 24 [Noatinaosmates if [Pinte denrance 72a [ute plate 1, 2p 20 oo Aso Ise plate a 30) ns 6648 308 365 fim d= | BE [Compensating pw a0 i waa i” (tamer pate) 1 23 2s 9699 308 330 i. 3% 30 ec 3,0 S644 308.365 8 of eto raion if Pista clsrance 738 (Ouse io ip 20 a1 163 4, (om: 2 EC] a CTEICEDI oe | ES [Compenssing pe zn a Tor ates G2 | 3% beep 1 23 13 sol a14388 2 ai or 3.0 3,0 9501 314391 3 INo. of friction nutaoes 1s Plate clearance 7.8PErpe ct iat 33a Cluteh K1 and K2 Spe) es) ees Ee ee ae eas 308330) 430 4544308 730 Daa Tae aT ‘aol 313 283 +5) use Weir sos 10) 54 508 4544308 330, oma CEUEICED] oso 14 188 oso sTe 501 314.388, 0501 309 329, a8 0 aon sn WI 23 | 38 | eae a oe $642 308 332 aor sta O01 314 3665) ‘501 14387 0801 314.385) 9501 314396Plat caarance mia ae] ‘Gs0r 312 20") wean SST) Ts] aes 0 0 002308 332 4642308 331 “eon Tago (S01 314 387 Note refi“) Install inner plate close to the piston, Note ref **) Outer plate one-sided coated ~ Install plate with the uncoated side facing the piston. ae Outer plate uncoated - install plate facing the piston. As second plate, a lining outer plate has to be installed. Attention! In case of plates with different thicknesses, the thinner plates must be abways installed on the backing plate side!abe I. EXAMPLE FOR PLATE INSTALLATION. ‘The following Draft shows the plate installation of the Clutch KY and KI! Ref. Draft : A Clutch KY (Plate installation-No. e.g. 12) A B Clutch KE (Plate installation-No. €.g. 22) Plate carrier Backing plate Piston Outer plates 2 ‘Cuter plates (one-sided costed) Compensating plate (Cuter plate uncoated) 7 = Inner plates & Compensating plate ‘Plate thicknesses Plate thicknesses (nner plate} decreasing decreasing Attention : In principle, the arrangement of the cuter and inner plates has to be carried out alternately. Starting with the piston side, the first plate must be one double-sided coated outer plate (Standard Version). Exception "AM" : In case of Plate installation-No. 22, 31 and a1, the first plate must be one one-sided coated outer plate, and in this case, the plate must be always in- stalled with the uncoated side facing the piston | Exception "B" : In case of Plate installation-No. 12 and (3, the first fe must be one double-sided uncoated outer plate (compensating plate). As second plate, one coated outer plate has to be installed. Now, pile up the inner and outer plates. alternately ieee |3.36 d 3.2.3.2 Install plate pack K& Install plate pack and replace backing plate. NOTE © Plate arrangement, see Plate installation, Page 3.35 ... 3.36 d! 139, Fix plate pack by means of soap cing. 140. Check plate clearance (Fij to NOTE. The plate clearance of the different clutches can be taken from the Table, Page 336 a. 336! In case of Plate installation-No. 40, ¢.g- = 2,0 o- 2,4 mm t Measure Dimension 1 from the end face of the plate carrier to the backing plate. Dimension 1 eg 5,3 mm a Place backing plate against snap ring until | contact is obtained (upwards), and determine | Dimension I. ‘laa See ie18 137 xamplc "B' Dimension 1 3,3 mm Dimension 1 Difference = Plate clearance NOTE : In case of deviations from the required plate clearance, correct by means of correspon- ding compensating plates. ‘The pre-assembly of the remaining clutches (K3, KV/K1 and KR/K2) has to be carried out accordingly. 3.2.3.3 Pre-assemble and install spur gear Ki ATTENTION : According to the Transmission Version, resp. ‘operating conditions, different spur gear bearings are possible, see corresponding Spare Parts List as well as Figures 143 and aad Ka, Version "A" (Fi 4 3 = Spur gear = Thrust washer 6 = Bearing inner race = Collar shim = 7 = Shim Spur gear K4, Version "B* (Figure 149) ta i i a aucune ting plate (optional) Install components 2 «+. 6 (Figure 143), resp. 2 .. 4 (Figure 194), replace thrust plate (1) and introduce spur gear until all inner plates are received. NOTE = Make thrust plate (2) adhere with greasea 3.38 3.2.3.4 Install plate pack K3 Install plate pack and check clearance. NOTE : Plate arrangement, see plate installation, Page 3.35 ... 3.36 d' Exchange cylindrical rollers 5 in sets only | Install Components 2 ... 5, replace thrust plate 1 (Arrow) and introduce spur gear until all. in- ner plates are received. NOTE : Make thrust washer 2 and cylindrical rollers 5 adhere with grease. 3.2.3.6 Install clutch Ko/K3 tend play of clutch 0,1 € 148 to Determine Dimension 1 from the flange-moun- ted surfacefaxle to the plane surface/housing, (Arrow). Dimension 1 eg. ZHI3 mm NOTE ¢ In case of spur gear bearing K4, Version "B" (Fieure 188). lay forked washer ard thrustMeasure Dimension II from the butting face Ibearing collers. to the flange-mounted sur- face. Dimension I e.g. 21,00 mm Example "C*, for the determination of the housing dimension 291,13 mm = 21,90 mm Place clutch on a suitable surface plate and determine Dimension Ill from the end face/ cylingrical rollers to the surface plate. Dimension I &.g. 227,20 am Puri Ds for the determination of the Dimension Ill e.g+ 227,20 mm End play eg. + 0,20 mm gives installation dimension = Clutch 227,40 mm Example "E", for the determination of the shim Housing dimension eg. 230,15 mm Installation dimension - Clutch - 227,90 mm Difference = Shim e.g. 2,75 mm Insert clutch K4/KR by means of lifting de- Yice inte the housing and position it.