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1.2 ALUMINIUM SAND-CASTING GEARBOX CONTROL 1.2.1 Version 1: With 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 35). aN AMeuNS = plug. HG 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.10 11 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.Squeeze in rectangles ring (Aerow 1 end en Fee Gring (Arrow 2) in the recest 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.3 ‘The Illustration on the left shows the com Ponents of the stator. Shim (constant, s = 1,0 mm) Ball bearing Thrust washer (5 = 1,5 mm) Free wheel inner ring oes a £ " 0 = Shim (optional, e.g. 5 = 0,2 mm) NOTE : ‘The stator end play is determined by means ‘of shim 10, see Example "B" | Insert bearing rollers, springs and spring caps (8, 7, and 6) according to the Illustra- tion on the left with grease into the bores of the free wheel hub. Place ball bearing (2) on the long hub side (29 mm) against shoulder, install thrust was- her (3) 3 = 1,5 mm and press free wheel in- ner ring against shoulder. Press spring (CS) into the free lindrical roller pairs (5) can be installed. The second roller pair has to be installed ‘opposite to the first roller pair - makes the installation of the remaining roller pairs ea~ sier ! (S) Guide plate 5870 345 020Mount thrust washer 3) 5 = 1,5 mm and press bearing against shoulder. Install shim (1) s = 1,0 mm and shaft washer (60x85x9,75). Opposite side = Install shim (1) 5 = 1,0 mm, shim (10) (optio~ nal e.g. 5 = 0,5 mm) and shaft washer (60x85x 4,7 5)e NOTE : The end play of the stator is determined by eae of shim (10) (e.g. s = 0,5 mm/empirical t However, a later check (Figure 39 — Example "B*) is absolutely essential | Mount housing washer (62xB5x0,5 mm) and bearing (60x85x3 mr). 2.09210 Install axial roller beatiog ant hoveing “ete her (62x85x9,79 mm) Mount new flat gasket and fasten flange by means of hex. head screws (mount flat was hers) on the impeller wheel. Torque limit (M38x18/8.8) 23.Nm NOTE: Pay attention to the radial installation posi- Sous ex head screws with Lectite (Type- Gane Bane "3 Mount flat gasket (Arrow). Determine Dimension 1 from the flange- mounted surface (gasket) to the plane sur- face/impeller wheel flange. Dimension 1 e.g. 88,05 mm CS) Straightedge 5870 200 022 (5) Gouge Moss 3870 200 066 Digital depth gauge 5870 200 072Meanire Dimension TI from the flange-moun- ted surface (converter impeller cover) to the housing washer. Dimension I exge 87,95 mm Example "B" = Dimension 1 Dimension 0 Difference = End NOTE In case of deviations from the permitted end play (max. 0,2 mm) correct by means of cor- ting shim 1 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 (M8x32/8.8) 23.Nm NOTE = Install flat washers Pay attention to the radial position, see mar- kings ! (S) Adjusting screw (M8) 5870 208 011 Squeeze the rectangular ring into the annular groove (Arrow) and engage it. NOTE : Install converter, see Page 3.77 | ait3. GEARBOX 3.1 DISASSEMBLY 3.1.1 CONVERTER CHARGE PUMP and Loosen hollow screw and remove delivery line. Loosen screwed connection (Figure 2) and se- parate engine connecting case from gear case by means of pry bars (Figure 3). Loosen hollow screw and remove delivery line. 3.01bearing cap. 5870 000 062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 5870 204 002 3.073.08 Fasten power take-off in a vise. the two snap rings, align them centrically and drive the drive dog wisionally about 5 .. 10 mm ahead (direction of Arrow). NOTE : For this step, an assistant is absolutely necessary ! (8) Ciretip pliers 5870 900 026 i ts ting (Figure 29), tap the drive dog loose and drive it out of the spur gear, po housing bore (Figure 30). NOTE = Pay attention to the released components 15870 300 006 5870 300 003 i i i i | I 3.1.3 LATERAL POWER TAKE-OFF Squeeze out circlip (housing interior). 34 REMOVE EMERGENCY STEERING PUP —s—sS ‘Loosen hex. nuts and separate emergency steering pump from gear case.3.1.3 REMOVE MULTI-DISK CLUTCHES NOTE: In case of Versions with Spur gear fia KL, the two set screws ( ve to be remo ved prior to the disassembly of the axle, see Figure on the right ! & Loosen hex. nuts and pull axle by means of Special device out of the clutch, resp. gear case. (3) Puller 5370 000 069 Lift clutch out of the gear case and deposit it. NOTE : Use lifting 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. (S) Lifting device 5870 350 O41 3.1.6 REMOVE COUNTERSHAFT ASSEMBLY Remove closing cover. Ban3.12 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.3.1.7 DISMANTLE MULTI-DISK CLUTCH Remove spur gear K1 and demount compo- nents. ‘Squeeze out snap ring. Remove plate pack. Preload compression spring, squeeze out cir~ clip and remove components. 4S) Assembly jig 5870 345 028 3.13,3.14 ‘Remove piston by means of clamping pliers. (5) Clamping pliers 5876 900 007 Pull needle bush out of the bore, using in- ‘ternal puller. NOTE, The disassembly of the clutch KV, KR/K2 and K4/K3 has to be carried out accordingly. (S) Internal puller 5870 300 O18 (3) Back-up tool 5870 300 0033.1.8 FINAL DRIVE - VERSION WITH DRUM BRAKE Remove lock plate and loosen hex. head screws. Pry output flange off the shaft. CS) Pry bar 5870 345 065 Tilt gear case 130°. Loosen hex. head screws. Separate brake drum from output flange. (S) Crow bar 3870 343 O71 315Remove lock plate and loosen hex. head screws. Pull output flange from the shaft. (S) Two-leg puller (5870 970 004 Unhook return springs and remove brake shoes. (5) Brake spring pliers 5870 900 006 Pry shaft seal out of the housing bore. (S) Crow bar 5870 345 O71 3.16‘Squeeze out circlip and remove shim. (S) Circlip pliers 5870 900 021 Loosen the two closing covers by central tap- ping and remove them. Remove upper oil retainer. 317Drive output shaft by means of striker out ‘of the output gear and remove it. ATTENTION In case of the Yersion with a mechanical speedometer, the speedometer-drive shaft (complete) has to be removed prior to: the disassembly of the output shaft (3) Puller 5870 023 O17 (3) Puller 5870 023 026 (5) Striker 5870 650 001 Remove output gear and plate. Squeeze out circlip and remove brake cam. (S) Set of external 5870 900 015 snap ring pliers Drive the pin out of the housing bore and remove it. 3.18g ye 8 2 3 case 180°, aft seal out of the housing bore. Squeeze out circlip and remove spacing was- 5870 900 O21 (S) Circlip pliers 3.193.2 REASSEMBLY 3.2.) 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 : Secure hex. head screw with Loctite (Type-No- 270)! Illustration on the right shows the components of the brake cam. cam has got contact on the housing without play and pressure. NOTE : scone hee head screw with Loctite (Type-No. Grease O-Ring (Arrow/Figure 92) ! 3.21For the fol steps pay attention to the 1 H hee ee 3 4 7 a ‘Squeeze in circlip 1. Tir gear cave 180" (CS) 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, sec Draft ! 3.23Fasten both plates by means of hex. head screws (install flat washers). Torque limit (M38/3.8) 23. Nm NOTE, ‘Secure hex. head screws with Lectite (Type- No. 270). Squeeze in circlip 8. (S) Clamping pliers 5870 900 O21 Press the speedometer-drive worm against shoulder. NOTE + In case of a Version without mechanical @ spacer has to be installed speedometer, instead of the speedometer-drive worm ! Thread up output shaft 9 until contact is obtained.Check _end ‘of the output shaft_beari =0,3 =. 0,5 mm 104... Example "A": Measure Dimension I from the end face/out- put shaft to the contact face (ball bearing). Dimension I e.g. 79,60 mm ('S) Digital depth gauge 5870 200 072 Determine Dimension Il from the end face/out- put shaft to the upper plane surface of the at Dimension It e.g. 79,10 mm Example "A" = Dimension 1 79,60 mm Dimension IL = 73,10 mm Difference = End play = 0,50 mm NOTE = In case of deviations from the required end play, correct by means of a shim (2), see Figure 95 | Press ball bearing against shoulder. 3.25Heat housing bore and thread up output shaft until contact is obtained. Fix ball bearing free of play by means of shim and circlip. (CS) Clamping pliers 5870 900 021 Install shaft seal with the sealing lip facing the oil chamber. NOTE : The exact installation ‘ition 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 T) 1 Grease sealing lip ! (S) Driver 5870 048 067 ‘The Figure on the left shows a Version with two shaft seals (Version with fording ability) Ee ee Fe oll chamber § inner shaft seal chamber. Sealing lip of outer shaft seal is showing outwards. The installation depth is given by applica- tion of the prescribed driver ! NOTE Fill space between upper and lower sealing lip with grease | (CS) Driver (5870 O88 067Install the two closing covers. NOTE Sia eae oe Sth tarts (Type-No. 270) t 5) Driver 35870 057 G15 (5) Handle 5870 260 02 n3 Heat output flange and assemble it until con- tact is obtained.Fasten output flange by means of disk and hex. head screws. NOTE : Wet the contact surface of disk and screw heads with sealing compound | Torque limit (M10/8.3) 46 Nm Fix hex. head screws by means of lock plate iver 5870 057 009 5870 260 o02 8 Assemble brake drum and fasten it by means of hex. head screws (mount flat was Torque limit (M10/10.9) 68 Nm (5) Adjusting screws (MIO) 5870 209 007Figure 119 shows a Version with 2 shaft seals (Version with fording ability). Installation ion: Sealing lip of inner ‘shaft seal is facing the oil chamber ! o Torque limit (M10/8.8) 46 Nm Fix hex. head screws by means of lock plate. (5) Driver 5870 057 009 (3) Handle 5870 260 002Press drive gear flat against the end face/ speedometer-drive shaft. Introduce speedometer-drive shaft and fix it by means of straight pin. (S) Driver 5870 088 072Torque limit (M8/8.3) 23. Nm Wet sealing surfaces with Loctite (Type-No.3.2.3 CLUTCH KA/K3 3.2.3.1 Pre-assemble plate carrier K4/K3 NOTE : The following steps (Figure 132 .. 138) have to be carried out on both sides of the plate carrier | Press needle bush carefully against shoulder, using drift (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) 1 (8) Drift 5870 506 055 ‘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 + — = Pressure side ! Ol profiled sealing rings and insert piston un- til contact is obtained. NOTE + Use installer (S$)! (S) Installer 5870 651 023 3.33 132 133 134 13sAssemble lower spring guide (1), ox Sea, haat eee oes guide G) Mount guide ring (#) and cirelip (9) (Figure 137), peeload compression spring and fix the components by means of circlip (Figure 138) - Assembly jig 5870 345 028PLATE INSTALLATION 1 Determine Plate installation-No. (Page 3.35) IL Table for plate installation (Page 3.36 ... 3.360) I Example with Draft (Page 3.364) Refit Dateanine Fate iniilotcnt No, reid tho ed ofthe corresponding Syare Parts Lit, The following List shows the abstract from a Spare Parts 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 aestncation Plate) must be identical with the corresponding Parts List of the Spare Parts List! ‘The Plate installations-No. ean be found on the ict Table margin of the following Pages (3.368 ... 3.366)! 3.35IL Table for Plate installation Clutch KV and KR Jrrceie ft een | ee fee [Our plate 3 2501 309330, 2 nner plats a S64 308 3 = 3 is ¥644 308 330%) > (Compensating pais 8 i wns 2s 4644 308 330 16 22.24 pie eS TE i 1 5 Z0 al mner plate, 4 25 3 | 8% [Compensating plate T 20 $648 108 329 4 3] (laser ple) os = 4644-308 330 2 Na. of friction arfaews 2 = Plate clearzoce 36.28 Gates a im is 4 a, anes plate Z 23 1s mex plato __ i. it [Compensating plate 7 1S TS Teta 308 1) 3 if (Outer plate) «20 20 4644 308 014°") i No.of frietion rurfaces 1s Plate clearance 22a F [Omens 5 20 Te 0501 300330 2g ay [Tamer plate 7 23 75 $544 308 350 2 [loner plc i: 8 2 [Compensating plate T 1 Ky Fea sie i) *| oes oa | ed ee i By i i Plats clearance as Gane plate 7 A) 20 TOL 308350 é toner plate 8 30, Fa $4308 365 = & [too piate ay i [Compensating plate ze 30 Tea 308 329 a (laanex pave) 1 ons 2s 4644 308-330 3 i = 30 oe 3.0 4644 308 365 2 Ne. of Rien rare ig Plate clearance 7.28 = [Outer plate oy 20 20 05013183 i |ij ie —* a g i [toner plate, Gs EE | compensating ine ie Boss 19/55 [imran eles aioe 3 |2 30 = 2 Na of friction murfaces Plate clesrance 3.368‘Gutch K1 and K2 ser 7 a Tse sm = oie z 3a S08 5 ise pt z a5 e307) j=———— es 2 or 25. MAL 308 330 of ficton acer Fie doermnes = t pn HTH 5 ene z Fm THEI ies t i asa i a 7 30 TOE 53 ) 25 4644 308 330 a ichon nabs Pie doarnes z z ny is oo i = 20 Fa [Ener pate z 0 © 3 e Dierpiae $ as 35 | a T 3a 30 3 was | ozs seitsen 0 : et thckon surthee 1 acs ia 7 = Fn i coe = ar 3 iJ or z a3 5 Coarse ss a 7 2 ie C301 314385 il wis | ws Siosiea E> eetiewrnaten i Pie cesnes Ta [0501 309 329 Plate invelinion No 0 Pine talon, 1 Plate inital No 32 3360* is D501 399338 * 13 6 a6 308 330 z 20. = $645 308332 T 33 as 6a 308 331" iz Ts “ea2 308 330 1 20 20 4942 908332 25 35 45423083. 16 Ha z 3 1s 01 3S i 30 30. ‘O50 313 80") 7 20 14 “et 300 T as a 9642 308 331°) 1s Ts AE 308 330 1 or 20 20 4542308332 oeBS 25 4612300331 ie Ea 3 3, is COLTTaIO 4 1s 6 0301 314367 z 20 4 Osoi 314383 T 25 zs D501 314 386°) 13 TS 0501 314387 1 20 20 0501 314385 25 or 35 0501 314.386 1. 2.20 Note ref. *) Install inner plate close to the piston. Note ref. **) Outer plate one-sided coated - Install plate with the uncoated side facing the piston. a 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 always installed on the backing plate side! 3386II, EXAMPLE FOR PLATE INSTALLATION The following Draft shows the plate installation of the Clutch KY and KI | Ref. Draf A = Clutch KV (Plate installation-No. e.g. 12) A B B = Clutch Kt won a (Plate installation-No. e.g. 22) Plate carrier Backing plate Piston Outer plates 2 (Outer plates (one-sided coated) ‘Compensating plate (Outer plate uncoated) 7 = Inner plates I | & = Compensating plate Plate thicknesses | Pate thicknesses (inner plate) decreasing, decreasing, Attention = In principle, the arrangement of the outer 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 In case of Plate installation-No. 22, 31 and 41, 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 1 Exception *B* : In case of Plate installation-No. 12 and 13, the first plate 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 again | 3.36 d3.2.3.2 Install plate pack Ke Install plate pack and replace backing plate. NOTE : Plate arrangement, see Plate installation, Page 3.35 ... 3.36 d ! Fix plate pack by means of snap ring. Check plate clearance (Figure 141 to Example NOTE : The plate clearance of the different clutches can be taken from the Table, Page 336 a ... 3.361 In case of Plate installation-No. 40, €.g- = 2,0 oe BGM 1 Measure Dimension I from the end face of the plate carrier to the backing plate. Dimension 1 e.g. 5,3 mm Place backing plate against snap ring until contact is obtained (upwards), and determine Dimension Il. Dimension I e.g. 32 mm 3.37 139 ~“¢ ) 149 141 14218 145 Dimension 1 3.3 mm Dimension IL = 3,2 mm Difference = Plate clearance 2,1 mm 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 (3, KV/K1 and KR/K2) has to be carried ‘out accordingly. 3.2.3.3 Pre-assemble and install spur gear K4 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 vat ‘Spur_gear Ko, Version "A" (Figure 13), ‘Thrust plate = Spur gear Thrust washer 6 = Bearing inner race Collar shim 7 = Shim Roller cage (2x) ‘Spur_gear Ko, Version "BY (Figure 144) Thrust plate Thrust washer ‘Spur gear Needle cage ‘Thrust washer ‘Thrust washer ‘Compensating plate (optional) Install components 2 ... 6 (Figure 1&3), resp. 2 sw» (Figure 144), replace thrust plate (1) and introduce spur gear until all inner plates are received. NOTE = Make thrust plate (2) adhere with grease !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 3 adhere with grease. 3.2.3.6 Install clutch K4/K3 Adjust end. of clutch e188 to Determine Dimension I from the flange-moun- ted surface/axle to the plane surfacefhousing (Arrow). Dimension I e.g. 231,13 mm NOTE: In case of spur gear bearing K4, Version "B* Gigue (ah, ley forked washer ond. thrust washer upon the plane surtace of the housing and measure up to the thrust washer. 3.39 Wa laTb3.40 Measure Dimension Il from the butting face Toearing rollers to the flange-mounted sur~ face. Dimension I e.g. 21,00 mm le "C, for the determination of the i ension Dimension 1 e.g. 251,15 mm imension I e.g =_21,00 mm, Difference = Housing dimension e.g. 230,15 rum Place clutch on a suitable surface plate and determine Dimension Ill from the end face/ cylindrical rollers to the surface plate. Dimension MI e.g. 227,20 ram Example "D", for the determination of the ieulatordineslen Dimension I e.g. 227,20 mm End play e.g. + 0,20 mm gives installation dimension = Glutch 227,40 mm Example “E", for the determination of the shim Housing dimension e.g. 230,15 mm Installation dimension - Clutch - 227,40 mm Difference = Shim e.g. 2,75 mm Insert clutch K4/KR by means of lifting de- vice into the housing and position it. (3) Lifting device 5870 350 O81Align clutch by means of drift and fix it pro- visionally.. CS) Drift $870 345 025 For the moment, tilt gear case 90* and the compl. clutch opposite to the drive side against shoulder until contact is obtained. Now, tilt gear case forward in the horizontal position. Pull drift downwards until the shim (e.g. = 2,75 me, see Example "E") can be inst Now, align the complete clutch as well shim by means of drift again and fix it. zt NOTE : Jin case of spur gear bearing KG, Version "A", without forked washer and thrust washer (Fi- gure: 153)! In case of spur gear bearing Kt, Version "B", another forked washer as well as one thrust washer have to be installed in addition to the shim. ATTENTION : Pay attention to the radial installation posi- tion of the forked washer ! Now, tilt gear case back in the original posi- 3.1Squeeze in and engage rectangular rings (1). Install O-Ring (2). NOTE Crossman align rectangular rings centrical- y- Install stud bolts, see Arrows | NOTE : Seowe the stud bolts with Loctite (Type-No. 270) 1 ‘Heat housing beres (about 90° C). (S) Hot-air blower 220 V 5870 221 500 (CS) Hot-air blower 10V 5870 221 501 Thread up axle (compl) until contact is ob- tained. 3.82—————— tS! 8.8) 23 Nm of the clutch 0,1 ... 0,3 mm SS" if necessary. base 5870 200 055 —Sstor 3870 200 057 9870 345 O71 es of the clutches K¢ and K3 by —_ essed air. ———————— are correctly installed, the ing of the clutches is clear- 3.43ear beari 1 = Thrust plate 8 = Spur gear 2 = Theust washer 9 = Plate 3 = Theust washer 10 = Hex. head screws 4 = Cylindrical rollers 11 = Thrust washer (short) 12 = Forked washer 3 = Disk 13 = Shim (optional) 6 = Cylindrical rollers (ong) 7 = Theust washer NOTE ‘Secure hex. head screws (M6/8.8 = 9,5 Nin) with Loctite (Type-No. 270) | Install components 2 ... 6 (Fig. 171 and 172 a) resp. 2 ... 10 (Fig. 172 b). ‘Replace thrust plate | (Arrow) and thread up Spur gear until all inner plates ate received. NOTE Make thrust washers and cylindrical rollers adhere with grease ! 3.2.3.3 Plate pack K2 Install plate pack and check clearance. \NOTI Plate arrangement, see Plate installati 3.35... 3.36 d 1 3.2.5. Pre-assemble and install spur gear K2 NOTE According to the Transmission Version, resp. ‘operating conditions, different spur gear bea- rings are possible, see corresponding Spare Parts Listas well as the following Figures (075 and 176) 1 307 17415 176 3.48 Spur_gear bearing K2, Version "A" Fig, 173 Pay attention to the installation position of ‘the roller cage (8), the larger inner diarne- ter of the brass cage is showing outwards (Arrow) | The broad butting faces of the angle rings are always facing the bearing rollers } Make thrust washer (2) adhere with grease ! ‘Spur_gear bearing KZ, Version "B" Fig. 176 NOTE = Pay attention to the installation position of the roller cage (9), the larger inner diame~ ter of the brass cage is showing outwards (Arrow) t Ih case of an equal inner diameter, the in- stallation position is optional. Make thrust washer adhere with grease 1Install components 2 ... § (Figure 175), resp. 2 a 6 (Figure 176). Replace thrust plate 1 (Arrow) and thread up spur gear until all inner plates are received. NOTE : Make: thrust washer adhere with grease 1 3.2.5.5 Install clutch KR/K2 Adjust_end of the clutch 0,1 Exam Insert forked washer and thrust washer (Ar- row) and measure Dimension I from the flange mounted surface to the thrust washer. Dimension 1 e.g. 252,20 mm Now, remove forked washer and thrust washer again. NOTE = In case of spur gear bearing KR, Version "B" (Figure 172 a), measure up to the plane sur- face/housing (without forked washer and Measure Dimension Il from the butting face/ bearing rollers to the flange-mounted surface. Dimension If ¢.g- 22,55 mm pe “E" for the determination of the Dimension 1 e.g. 252,20 mm Dimension Il e.g. = 22,55 mm Difference = Housing dimension e.g. 229,65 mm, 3.09 13.50 Put the clutch on a suitable surface plate and determine Dimension Ill irom the end face/cylindrical rollers te the surface plate, see Figures 180 and 181 ! Dimension Ill exge 227,65 mm le "G" for the determination of the installation dimension Dimension II e.g. 227,65 mm End play eg. + 0,20 mm gives Installation Dimension = Clutch eg. 227,85 mm Example "H" for the determination of the shim Housing dimension e.g. 229,65 mm Installation dimension = Clutch eg. = 227,85 mm Difference = Shim e.g. s= 1,80 mm Insert clutch KR/K2 in the housing, using lifting device. NOTE : The of the shims and the fixing ‘of the clutch has to be done along with the clutch KV/K1 ! (S) Lifting device 3870 350 081